MAINTENANCE

HYDRAULIC SYSTEM

The hydraulic system in your truck is powered by gear type Should it be necessary to lower the operator compartment in
pumps. One pump supplies pressure for the main and an emergency or for service, this can be done by operating
auxiliary lift. Another pump supplies pressure for all the the manual emergency lowering valve even with the battery
accessory functions. disconnected.
/I\ WARNING
Maximum pressure is limited by relief valves for all lift and
accessory functions. Normal relief valve settings are noted Before using Manual Lowering Valve warn op-
on the hydraulic schematic which is applicable to your unit. erator to keep all body members within the
operator's compartment. Make sure the forks are
The following is a brief description of the hydraulic system for clear of the rack. Close valve immediately if
the T S P , which is typical of current standard units. (Your unit chains become slack.
may vary, see appropriate schematic in this manual).
All lift cylinders have velocity fuses to prevent lowering
A100 mesh strainer, mounted in the reservoir, filters hydrau- should a major hydraulic failure occur.
lic oil as it enters the suction line of the main lift pump or
accessory pump. A manifold diverts the flow to either of the An accumulator is in the traverse circuit to cushion the stop
above pumps. Pressurized oil from the lift pump flows when full left or right.
through a servo lift valve (SV-1), a combination valve con-
sisting of integral relief valve (RV-1 & RV-2) and solenoid As the forks are pivoted full clockwise or counter-clockwise
valves (SV-2 & SV-3), a flow control valve and to the free lift, the pivot latch cylinder is actuated to lock the forks in this
main lift or auxiliary lift cylinders. When the control handle is position.
positioned for lowering the solenoid valve (SV-2) shifts and
the oil in the lift cylinder is permitted to return to the reservoir The brake circuit is equipped with a dual pressure switch that
at a rate controlled by the operator through SV-1. The flow will maintain proper hydraulic pressure to the brake cylin-
control meters maximum flow rate of the oil returning to the ders.
reservoir, controlling the cylinders maximum rate of descent.
A lift circuit accumulator cushions the lowering when the
control handle is moved from the lower position. A manual
emergency lowering valve can be utilized if an elect'ical
malfunction prevents the lift cylinder(s) from lowering. A 10
micron return line filter filters the oil as it returns to reservoir.

Pressurized oil from the accessory pump when required,

enters the brake manifold assembly containing solenoid
valves (SV-6, SV-7, SV-8 & SV-9), and goes on to the drive
wheel brakes and load wheel brakes. Pressure in the brake
accumulator will release the brakes when the brake pedal is
released. Oil from the accessory pump enters the traverse
cushion manifold. When the appropriate control lever (pivot)
is actuated, oil from the pivot control valve flows through the
pivot manifold assembly and is diverted to the appropriate
pivot cylinder. When the appropriate control lever (traverse)
is actuated, oil from the the traverse cushion manifold
containing solenoid valve (SV-12) flows through the traverse
valve to the traverse manifold onto the hydraulic motor
supplying power to traverse. The traverse manifold assem-
bly containing solenoid valves (SV-4, SV-5, SV-10) will divert
oil to the fork manifold and to the fork cylinders when the
traverse function is complete. The direction of spool move-
ment determines the direction of the accessory functions.
The oil travels through the system as above returning to the
reservoir.

Crown 1988 PF8168-1 Rev. 2/99 Printed in U.S.A.

06 REV. 2/99
M2.0-19.0-001 M2.0-19.0-001
 CROUJh MAINTENANCE
Relieving Pressure f r o m Lift Hydraulic System
/f\ WARNING
1. Lower platform & forks to lowest position.
/WO/D H/Gf/ PRESSURE FLUIDS—Escaping
fluid underpressure can penetrate the skin caus- 2. Turn key switch to OFF position.
ing serious injury. Relieve pressure before dis-
connecting hydraulic lines. Tighten all connec- 3. Open emergency manual lowering valve, located at
tions before applying pressure. Keep hands and upper right hand rear of the power unit. After the
body away from pin holes which eject fluids under hydraulic pressure is totally relieved close valve.
high pressure. Use a piece of cardboard or paper
to search for leaks. Do not use your hand. 4. Perform maintenance service on lift hydraulic system.

Any fluid injected into the skin under high pres- 5. Aftermaintenance service iscompleted and all hydrau-
sure should be considered as a serious medical lic fittings have been replaced and tightened, turn key
emergency despite an initial normal appearance switch to ON position.
of the skin. There is a delayed onset of pain, and
1
serious tissue damage may occur. Medics atten- 6. Follow Lift Cylinder Bleeding procedure described in
tion should be sought immediately by a specialist section M8.0 of this service manual.
who has had experience with this type of injury.
7. Check lift hydraulic system for proper operation. If the
lift hydraulic system does not operate properly be-
cause of remaining air in the hydraulic system, repeat
the lift cylinder bleeding procedure as required.

Crown 1988 PF-8168-2 Rev. 9/93 Printed in U.S.A.

03 REV . 9/93
M2.0 - 19 - 002 M2.0 - 19 - 002
 craiun MAINTENANCE

Reservoir
NOTE
With all cylinders in the retracted position and after all air has
Do not tighten filter with the use of a wrench. A
been bled from the hydraulic system, the oil level in the
wrench should only be used for removal of the filter.
reservoir is to be between 1/2" (13mm) to 2" (51mm) on the
reservoir oil level dipstick. The total capacity of the hydraulic
Use only a good grade of hydraulic oil such as Mobil DTE 24
system at this level should be approximately 22 gallons (100
(Crown No. 063001-001) or equal. On trucks equipped to
litres).
operate in below freezing temperatures, a mixture of 20% Mobil
DTE 24 (Crown No. 063001-001) or equal and 80% Mobil Aero
Hydraulic Lines and Fittings HFA (Crown No. 063001-006) or equal is recommended.

1. Blow air through all hose and lines to remove loose

NOTE
particles before installing. Any rubber hose with wire
braid inner construction or any steel tube lines which
Do not use hydraulic brake fluid.
have been collapsed or kinked are permanently dam-
aged and must be replaced even if the damage is not
DRIFT TEST
externally visible.
All drift tests should be conducted with a capacity load (refer to
2 Flexible hose shall be replaced if it collapses in its serial plate for the rated capacity of your truck). The material
normal operating position. used for the test load must be evenly stacked within the limits
of a four foot square pallet and must be secured to the fork
3. All hoses and lines are to be clear of any surface or carriage with the forks spread to their maximum width.
edge which will cause damaging wear and cuts, or on
which they can become caught. NOTE

4. All connections are to be leak free. The lift measurement is to be taken from the tip
of the fork to the floor.
5. The beaded elbows in suction ports of all pumps must
be positioned such that the suction hose retains its full / l \ CAUTION
volume flow, and does not collapse.
Never stand or work under a suspended load.
WARNING
Lift Drift Test
AVOID HIGH PRESSURE FLUIDS—Escaping
fluid underpressure can penetrate the skin caus- Elevate the test load on the auxiliary mast approximately 1 to 2
ing serious injury. Relieve pressure before dis- feet (305 to 610mm) and raise the operator's compartment until
connecting hydraulic lines. Tighten all connec- the second stage mast has raised approximately 2 to 3 feet (610
tions before applying pressure. Keep hands and to 915mm). Shut off truck. After five minutes, measure the
body away from pin holes which eject fluids distance the forks have drifted. Drifting in excess of 112" (13mm)
under high pressure. Use a piece of cardboard or per minute, over a period of five minutes (2 1/2" or [64mm] total
paper to search for leaks. Do not use your hand. drift) is considered unacceptable. The five minute duration of
this test is necessary due to the centering time required for the
Any fluid injected into the skin under high pres- control valve spool(s).
sure should be considered as a serious medical
Occasionally, a slight creep of the fork assembly may occur due
emergency despite an initial normal appearance
to internal leakage in the piston pak, but it can also be caused
of the skin. There is a delayed onset of pain, and
by leakage in the check or control valve. To seat these valves
serious tissue damage may occur. Medical atten-
properly when this occurs, raise and lower the forks to flush out
tion should be sought immediately by a specialist
any foreign material from the valve seat.
who has had experience with this type of injury.
A thorough check for leaks in the sytem should be conducted if
Filter abnormal oil losses occur. The hydraulic system is designed to
eliminate mechanical damage even if fittings become loose.
The spin on filter cartridge has been tightened by Crown.
When replacing filter, apply a film of oil 063001-001 to the
seal and hand tighten until seal snugly contacts filter head.

Crown 1988 PF-8168-3 Rev. 1/94 Primed in U.S.A.

04 REV. 1/94
M2.0 - 19 - 003 M2.0 - 19 - 003
 MAINTENANCE
CROUJh
MAIN & AUX. LIFT/
DUAL PRESSURE SWITCH LOWER MANIFOLD ASM.
(BPS1 & BPS2) (INCLUDES RV1, RV2
SV2 & SV3)

MAIN LIFT MOTOR

MANUAL LOAD (M1)
LOWERING VALVE

ACCUMULATOR
(LIFT CIRCUIT) FLOW CONTROL VALVE
(AUX. LIFT CIRCUIT)

MAIN LIFT PUMP

(PI)

LOAD LOWERING
VALVE

SERVO VALVE ASM.

(INCLUDES SV1)

DRIVE UNIT BRAKE MANIFOLD ASM. ACCESSORY PUMP

BRAKE CYLINDERS (INCLUDES RV3, SV6, (P2)
SV7, SV8 & SV9)
POWER UNIT COMPONENT LOCATION
ILLUSTRATION 2-3

POWER UNIT & MAIN FRAME COMPONENT LOCATION

o7B4-oi
S ILLUSTRATION 2-4

Crown 1968 PF-8168-4 Ftev.3/93

. Printed in U.S.A.

03 REV. 9/93
M2.0- 1 9 - 0 0 4 M2.0- 1 9 - 0 0 4
 MAINTENANCE

LOAD HANDLER COMPONENT LOCATION

ILLUSTRATION 2.-5

k= -» TRAVERSE CONTROL
VALVE

AUX. LIFT PIVOT

CYLINDER
VALVE

TRAVERSE CUSHION
MANIFOLD ASM.
FORK MANIFOLD ASM
(INCLUDES PRF1,
(INCLUDES FDV)
PRF2 & SV12)

VELOCITY
FUSE

FORK EXTEND
CYLINDERS

LOAD HANDLER & PLATFORM COMPONENT LOCATION

0785S ILLUSTRATION 2r6

Printed in U.S.A.
Crown 1 9 8 8 P F - B 1 6 8 - 5 Rev. 9.91
02 REV. 9/91
M2.0-19-005 M2.0-19-005
 MAINTENANCE

HYDRAULIC COMPONENT CHART

Chart 2-1 illustrates which motor operates, when the manual valves are operated and which solenoid valves are energized
for each hydraulic function, (e.g. During main lower, the solenoid valves SV-1 and SV-2 are energized.)

PUMP MANUAL CONTROL

FUNCTION MOTOR VALVE * SOLENOID
LIFT ACC'Y. PIVOT TRAVERSE VALVE
Main Raise (Note 1) X SV1
Main Lower SV1.SV2
Auxiliary Raise (Note 2) X SV1
Auxiliary Lower SV1, SV3
Brake Release SV6, SV7
Brake Applied (0 - 2.3 MPH) (Note 4) SV9
Brake Applied (2.3 - 6 MPH) (Note 3)
Hyd. Brake Recharge (Note 5) X SV8
Traverse In Cushion X X
Traverse Out of Cushion X X SV12
Fork Extend - Right X X SV4, SV5
Fork Retract - Right X X SV4, SV5
Fork Extend - Left X X SV4, SV5, SV10
Fork Retract - Left X X SV4, SV5, SV10
Pivot X X SV11

"Indicates component is energized for function to operate.

CHART 2-1

NOTE1: Relief valve 1 (RV-1) limits the capac:. a - ; s aa-stable.

NOTE 2: Relief valve 2 (RV-2) limits the capacity and is adjustable.
NOTE 3: Above 2.3 MPH, load wheel and drive unit brakes are applied.
NOTE 4: Below 2.3 MPH, only the load wheel brakes are applied.
NOTE 5: Controlled by the brake pressure switch (BF5

Crown 1988 PF-8168-6 Rev. 9/91 Printed in U.S.A.

02 REV. 9/91
M2.0 - 19 - 006 M2.0 - 19 - 006
 MAINTENANCE

FREEZER PREPARATION

Crown trucks may require a mixture of low temperature

hydraulic oil, Crown P/N 063001-006 (gal.), blended with
standard hydraulic oil, Crown P/N 063001-021 (gal.) when
used in a freezer or cooler. 100% low temperature oil is too
thin for most cold storage operations and therefore could
shorten the life of cylinder packings and pumps if used in
higher ambient temperatures.

NOTE

Trucks equipped with velocity fuses may experi-

ence staging issues if an insufficient mix of low
temperature oil has been used.

For truck applications operating continually in temperatures

at or above 32 degrees Fahrenheit, use 100% standard
hydraulic oil.

For truck applications operating continually at temperatures

of 32 Degrees Fahrenheit or below, use a 80/20 Mend, 8 0 %
low temperature (063001 -006) and 2 0 % standard hydraulic
oil (063001-021).

The proper mixture of freezer hydraulic oil will ensure the

best and most efficient operation of your Crown equipment

Standard Hydraulic Oi
(063001-001 [100%])

80/20 Mix of Low-Temp

(063001-006 [80%] &
Standard Hydraulic Oil
(063001-021 [20%])

TS/TSP Models

ILLUSTRATION 2-7

Crown 1988 PF8168-7 Rev. 1/98 Printed in U.S.A.

05 REV. 1/98
M2.0-19.0-007 M2.0-19.0-007
 caaiun MAINTENANCE

HYDRAULIC COMPONENT CHART

Chart 2-1 illustrates which motor operates, when the manual valves are operated and which solenoid valves are energized
for each hydraulic function, (e.g. During main lower, the solenoid valves SV-1 and SV-2 are energized.)

PUMP MANUAL CONTROL

FUNCTION MOTOR VALVE * SOLENOID
LIFT ACC'Y. PIVOT TRAVERSE VALVE
Main Raise (Note 1) X SV1
Main Lower SV1 ,SV2
Auxiliary Raise (Note 2) X SV1
Auxiliary Lower S V 1 , SV3
Brake Release SV6, SV7
Brake Applied (0 - 2.3 MPH) (Note 4) SV9
Brake Applied (2.3 - 6 MPH) (Note 3)
Hyd. Brake Recharge (Note 5) X SV8
Traverse In Cushion X X
Traverse Out of Cushion X X SV12
Fork Extend - Right X X SV4, SV5
Fork Retract - Right X X SV4, SV5
Fork Extend - Left X X SV4, SV5, SV10
Fork Retract - Left X X SV4.SV5.SV10
Pivot X X SV11

'Indicates component is energized for function to operate.

CHART 2-1

NOTE 1: Relief valve 1 (RV-1) limits the capacity and is adjustable.

NOTE 2: Relief valve 2 (RV-2) limits the capacity and is adjustable.
NOTE 3: Above 2.3 MPH, load wheel and drive unit brakes are applied.
NOTE 4: Below 2.3 MPH, only the load wheel brakes are applied.
NOTE 5: Controlled by the brake pressure switch (BPS).

Crown 1988 PF-8168-7 Rev. 9/91 Printed in U.S-A.

02 REV. 9/91
M2.0- 1 9 - 0 0 8 M2.0- 1 9 - 0 0 8
 HYDRAULIC SCHEMATIC SYMBOLS

VENTED RESERVOIR
with lines above fluid level
ELECTRIC MOTOR
unidirectional single speed

VENTED RESERVOIR
with lines below fluid level

ELECTRIC MOTOR
unidirectional variable speed

FILTER or STRAINER

HYDRAULIC LINE HYDRAULIC PUMP

with full flow (plumbing - may be fixed displacement unidirectional
tubing, hose, or flow passage in
manifold)

PILOT or DRAIN LINE

limited flow HYDRAULIC MOTOR
bi-directional

LINES CROSSING

A ) GAUGE
LINES CONNECTED pressure

_r\_\ QUICK DISCONNECT

lv^~ (disconnected)
GAUGE
temperature

PLUGGED PORT
(test port)

ACCUMULATOR
gas charged diaphragm type
-{^^)— FLOW METER

2128

Crown 1979 PF5066-1 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1-00.0-001 M2.1-00.0-001
 HYDRAULIC SCHEMATIC SYMBOLS

PRESSURE SWITCH ACTUATOR MANUAL

CYLINDER SPRING
double acting unequal area (bias to normal de-energized position)
r r

CYLINDER
double acting equal area
(steer) (double end) SOLENOID
single coil or winding

CYLINDER
AA A,
VVV single acting spring returned
(rod end vented)

HYDRAULIC PILOT OPERATED

CYLINDER
single acting ram type
SOLENOID
pilot operated

CYLINDER
single acting with cushion
SOLENOID DUAL

COMPONENT ENCLOSURE
manifold block
SOLENOID PROPORTIONAL

VALVE PILOT CHECK

ACTUATOR MANUAL LEVER
(pilot to open)

Crown 1979 PF5066-2 Rev. 1/02 Printed in U S A

03 REV. 1/02
M2.1-00.0-002 M2.1-00.0-002
 CRQUJh HYDRAULIC SCHEMATIC SYMBOLS
3561-02

ORIFICE THROTTLE
fixed Oi VALVE SHUTTLE

ORIFICE THROTTLE
adjustable

VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
PRESSURE COMPENSATED
fixed

FLOW CONTROL
PRESSURE COMPENSATED
fixed with reverse flow bypass
FLOW DIVIDER/COMBINER

H H
FUSE VELOCITY
BYPASS FLOW CONTROL
regulated flow
pressure compensated

VALVE RELIEF VALVE MANUAL SHUTOFF

fixed setting

TORQUE GENERATOR
VALVE RELIEF
adjustable

—o

L STEER UNIT
T"
VALVE CHECK hydrostatic
P- R

Crown 1979 PF5066-3 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1-00.0-003 M2.1-00.0-003
 CAQUJh HYDRAULIC SCHEMATIC SYMBOLS
3562-02

VALVE
2 way 2 position VALVE
3 way 2 position
spring bias, solenoid control

VALVE
3 way 2 position

VALVE
4 way 3 position
dual spring centered,
manual lever control
VALVE
4 way 2 position

VALVE
4 way 3 position

X X

NOTE: The type of valve

depends on the number of
spools found in the
VALVE component enclosure
(Triple spool valve
2 way infinite positions shown)

VALVE
4 way infinite positions

Crown 1979 P F 5 0 6 6 - 4 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1-00.0-004 M2.1-00.0-004
 MAINTENANCE

9221 ILLUSTRATION 1

PUMP - GEAR

Overhaul the pump only in a clean, dust-free location, using then be removed with the use of a seal removing tool. Be
clean tools and equipment. Dirt or grit will damage :ne highly careful not to damage the mounting flange seal bore or the
polished machined surfaces and will result in leakage or drive shafts sealing surface.
premature failure of the pump.
OIL SEAL REPLACEMENT
Before beginning the disassembly, scribe match mar-:; :
the body assembly, the end cover and mounting flange to 1. Make sure the seal housing in the pump mounting
insure that the pump will be reassembled properly. This flange is clean and free from burrs.
pump can be assembled for either clockwise or counter-
clockwise rotation as viewed from the end of the splined drive 2. Pack the space between the lips of the seal with a high
gear assembly. Arrows are molded in to the body assembi melting point, mineral based grease.
and the word "ROTATION" appears on the mounting flange
to aid in determining the pumps rotation. Note which direc- 3. Seat the oil seal.
tion the arrow is pointing next to the word "ROTATION" prior a. If the mounting flange has been removed:
to disassembly. Start the oil seal squarely into the housing, with the
garter spring facing inward and press home to the
OIL SEAL REMOVAL full depth of the recess.
b. If the pump is assembled:
The oil seal (index 11) is best removed by applying pressure Slide an "Assembly Sleeve" (available from Crown
simultaneously to the pump inlet and outlet ports. This has [#93170]) over the shaft splines until it comes in
the effect of pressurizing the seal cavity and forcing out the contact with the shaft shoulder. Lightly grease the
oil seal while ensuring that the pressure on each side of the sleeve. Slide the oil seal, with the garter spring
lobe seals (item 3 & 4) is equalized so that these seals are facing inwards, over the sleeve and start it squarely
not displaced. If the oil seal is distorted and leaking badly, it into the housing.
may not be possible to build up sufficient pressure to remove
it in this way. In this case, disassemble the pump as far as 4. Press the seal into the full depth of the recess.
step 5 of the "DISASSEMBLY PROCEDURE" and clamp the
mounting flange securely in a soft-jawed vice. The seal can 5. Remove the Assembly Sleeve.

1
Crown 1982 PF5372-1 Printed in U.S./

M2.1-10.0-001 M2.1-10.0-001
 dlOHJh MAINTENANCE

PUMP DISASSEMBLY the body should be rejected. It is not advisable to fit worn
bushings into a new body. Check to make sure the two
1. Remove the bolts which hold the pump to the lift motor. hollow dowels are not loose.

2. Lightly mark or scribe the end cover (index 2), the body Composite Bushings
(index 7) and the mounting flange (index 10) to ensure
re-assembly in the correct relationship. Also note the Examine the bearing inserts for signs of wear and check the
direction of rotation of the pump. bushing faces adjacent to the gears for scoring or pitting.
Make sure the holes and slots in the bushings are not
3. Loosen the bolts and lockwashers (index 1) and pull plugged. Light scored on the bushings faces can be polished
out the bolts. out on a lapping plate.

4. Remove the end cover (index 2) and carefully lift out the NOTE
two backing washers (index 3), the lobe seals (index 4) If new bushings are to be used in an old body, check
and the body "O" ring seals (index 6). The body seal is for any burrs at the edge of the wear track. If present,
a moulded rubber seal on early pumps but changed to this burr must be polished out or it may hold the
an "O" ring on newer units (Specify when ordering). bushing faces away from the gears and increase the
internal leakage.
5. Fit an "Assembly Sleeve" tool (available from Crown
[#93170]) over the splines on the drive shaft before Gears
withdrawing the mounting flange. Lightly tap the mount-
ing flange clear of the two hollow dowels in the pump Examine the gears for discoloration, caused by overheating.
body and slide it squarely off of the shaft. Check the shafts for scoring. Make sure the contact marks on
the teeth are evenly distributed across each tooth surface
6. Carefully lift out the body "O" ring seal (index 6), the two and that none of the teeth are chipped.
backing washers (index 3) and the lobe seal (index 4).
NOTE
7. Hold the pump body vertically with the mounting flange
end downward and with one hand underneath to pre- Bushings and/orgears are matched for widths within
vent the bushings (index 5) from falling out. Tap the .0002" (0.005 mm) and can only be sold and re-
side of the body with a rawhide mallet to dislodge the placed as a matched pair.
lower bushings, and slide them carefully out of the
body. Keep the bushings as a pair and place them on End Cover
or near the mounting flange.
Examine the cover to insure flatness and inspect for scoring
and pitting.
8. Invert the body and lift out the drive (index 9) and the
idler (index 8) gears. Mounting Flange

9. Remove the remaining pair of bushings as described in Check for damage and check the condition of the oil seal. If
step 7 and place on or near the end cover. the seal needs replacement refer to the "Oil Seal Replace-
ment" section.
PARTS INSPECTION

Wash all metal parts thoroughly with a good cleaning fluid.

Inspect, in the order disassembled, for wear and damage.

Body

To obtain high efficiency the design allows for the tips of the
gear teeth to wipe the walls of the body bores when the pump
is running. Pressure will force the gears against the inlet side
of the bores a wear pattern will be visible in this area. If
excessive wear of the bushing inserts or gear journals
occurs this wear pattern will deepen to form a step in the
bore. Examine the body bores and if a pronounced step is felt 9222 ILLUSTRATION 2
Crown 1982 P F 5 3 7 2 - 2 Primed in U.S.A.

M2.1-10.0-002 M2.1-10.0-002
 CRQlUh MAINTENANCE
CLOCKWISE ROTATION
COVER END MOUNTING FLANGE END

BUSHING LOBES
BUSHING LOBES FLAT

ASSEMBLE DRIVE GEAR ASSEMBLE DRIVE GEAR

IN THIS BORE IN THIS BORE

COVER END MOUNTING FLANGE END

BUSHING
FLAT LOBES FLAT

ASSEMBLE DRIVE GEAR

ASSEMBLE DRIVE GEAR
IN THIS BORE
IN THIS BORE
COUNTER-CLOCKWISE ROTATION
9223 ILLUSTRATION 3
PUMP REASSEMBLY

Make sure that all pump components are perfectly clean and 5. Pick up the mounting flange bushing complete with
lubricated with the hydraulic oil to be used in the pump, prior lobe seal and backing washers, and slide them into the
to assembly. body bores with the lobes facing outwards and away
from the flat at the intersection of the body bores. The
1. Prepare the bushings (index 5) for mounting flange end bushings must be inserted squarely into the bores and
of the body for assembly as follows: must be kept square to each other. Do not use force
(Refer to illustration 2) when installing the bushings. If the bushings should
Place the bushings on the workbench with their lobes cock in the bores, remove them and examine for
up and the flats in contact. Lubricate the lobe seal scored body walls. Light scoring can be stoned out with
(index 4) with a mineral based grease and fit it around a fine grit hand stone.
the bushing lobes. Fit a backing washer (index 3) inside
each lobe seal. When fitted correctly, the backing 6. Lubricate the body seals "O" ring (index 6) with a
washer must be level and flush with the top surface of mineral based grease and seat it in the body.
the bushing lobes.
7. Refer to illustration 3 to find the position of the drive
2. Prepare the bushings for the cover end of the body for gear bore for the direction of rotation you require. Lay
installation into the pump in the same manner. the pump body on its side and slide the drive gear
(index 9) through the drive gear bore (as called out in
3. Pack the space between the lips of the oil seal (index illustration 3) so that the shaft protrudes out of the
11) with a high melting point, mineral based grease. hollow dowel end of the body.

4. Pick up the body and hold it with the hollow dowels up

and with the fingers of one hand inside the bores of the
body, ready to support the bushings.
Crown 1 9 8 2 P F 5 3 7 2 - 3 Printed in U.S.A.

M2.1-10.0-003 M2.1-10.0-003
 CRQUJh MAINTENANCE

8. Slide the "Assembly Sleeve" (#93170) over the end of START UP PROCEDURE
the splined shaft. Hold the drive gear journal with one
hand and slide the mounting flange (index 10) squarely A pump that has been re-assembled with new gears, bush-
over the shaft and onto the two hollow dowels, flush ings or body must be carefully broke-in before it is subjected
against the body. The "Assembly Sleeve" provides a to full load working conditions.
lead-in forthe oil seal. Remove the "Sleeve" and clamp
the mounting flange in a soft jawed vice with the pump When test rig facilities are not available the following proce-
body above the flange. If the sleeve is stuck on the dure must be carried out:
splines it can be removed by tightening a 1/4"-28 bolt
into the end of the "Assembly Sleeve". 1. Install the pump on the application.

9. Check that the bushings are flush against the mounting 2. Where the pump speed is variable set the speed to
flange face and that the lobe seals (index 4) and 1500 rev/min; otherwise run the pump at its normal
backing washers (index 3) have not become dis- operating speed.
lodged. Check to see that the arrow on the body,
adjacent to the word "ROTATION" is pointing in the 3. Run the pump at this speed for a period of 10 minutes
correct pump rotation. at minimum pressure, that is, with the hydraulic system
unloaded.
10. Mesh the idler gear (index 8) with the drive gear. If the
original gears are being replaced on a new shaft, make 4. If the pump operating pressure can be directly con-
sure that the marked side of the teeth are in contact so trolled, ensure that the pressure is progressively in-
the bedded-in position of the teeth is maintained. creased up to full working requirements over the first
hour of operation. In circumstances where the pres-
11. Pick up the bushings for the end cover side of the sure cannot be directly controlled the same effect can
pump, complete with lobe seals and backing washers be obtained by progressively increasing the work load
and slide them over the gear journals with the lobes on the machine, over the same period of time.
facing outward and away from the flats in the bores.
Again, the bushings must be installed squarely and 5. During this period make frequent checks of the pump
without force. casing temperature, or the oil temperature, if a tem-
perature gauge is included in the system. The tempera-
12. Lubricate the body seal "O" ring (index 6) and seat it in ture should not exceed that experienced under normal
the body. working conditions. If the temperature does rise exces-
sively then it is possible that the pump has been
13. Place the end cover in position, aligning the scribe assembled incorrectly and it must be dismantled to
marks made earlier. check this. If no fault is found then further period of
running-in at low pressure, as in step 3, must be carried
14. Insert the bolts and lockwashers into the body and out.
hand tighten into the tapped holes in the mounting
flange. Apply a torque load of 4.7 to 5 kgm (34 to 36 ft
lbs.) to each bolt head.

15. Pour a small amount of hydraulic oil into the ports and
check the pump for freeness and direction of rotation.

Crown 1982 PF5372-4 Pnnted in U S A .

M2.1-10.0-004 M2.1-10.0-004
 MAINTENANCE

^ 11

ILLUSTRATION 2.1-1

PUMP-GEAR CAUTION

Preparation for Disassembly Never insert a screwdriver or other similar

instrument between the housing and the
The pump overhauling should be performed in a
stator for the purpose of prying the two
clean, dust-free l o c a t i o n , using clean t o o l s and
halves apart as permanent damage may
equipment. Dirt or grit w i l l damage the highly
result.
machined surfaces and w i l l result in leakage or
premature failure of the p u m p . Once the h o u s i n g s are separated, remove the dowel
pins (item 18). A l s o remove t h e idler gear and drive
Before proceeding w i t h the p u m p d i s a s s e m b l y , scribe
gear a s s e m b l i e s w h i c h i n c l u d e s the retaining rings
match marks on the stator (item 8) and the gear
(item 11), the gears (item 12), the keys as well as the
housing (item 19) to insure that the p u m p w i l l be
idler shaft ( i t e m 14) and t h e drive shaft (item 15).
reassembled in the same manner as it was shipped
When r e m o v i n g the plastic s h i m , located between the
f r o m the factory. If the stator or gear h o u s i n g is
gear h o u s i n g face and the s t a t o r face, note the color
replaced during overhaul, scribe a match mark on the
of the s h i m . These s h i m s are supplied in different
new part in the same location as on t h e part it
c o l o r s w h i c h c o r r e s p o n d s t o different t h i c k n e s s e s .
replaces.
W h e n replacing the s h i m , t h e s a m e color s h i m m u s t
Pump Disassembly be reinstalled as was r e m o v e d . Further disassemble
the shaft a s s e m b l i e s and place all c o m p o n e n t s in the
NOTE solvent.
All item numbers refer to their respective Part I n s p e c t i o n , Evaluation and Replacement
parts on the exploded view (Illustration 2.1-1).
T h o r o u g h l y w a s h all p u m p c o m p o n e n t s in a good
Clean the outside of the p u m p w i t h a good grade grade solvent and blow d r y . Lay the cleaned
solvent and thoroughly dry. Secure the unit in a vice
c o m p o n e n t s on a dirt-free bench or shop-cloth and
(using light clamping pressure) at the area of the
i n d i v i d u a l l y inspect each part for the s y m p t o m s
m o u n t i n g flange ( " A " ) . Loosen and remove the eight
mentioned below:
(8) assembly screws (item 20). Separate the gear
housing (item 19) from the stator (item 8). It may be
necessary to lightly tap the sides of the h o u s i n g to
facilitate the separation.

Crown 1984PF-5875-1 Printed in U . S . A .

M2.1 - 1 8 - 0 0 1 M2.1 - 1 8 - 0 0 1
 MAINTENANCE

DRIVE SHAFT (item 15) — Inspect the drive shaft for GEAR HOUSING (item 19) — Inspect the gear
wear or cracking o n the end of the shaft, grooving on h o u s i n g ' s gear pocket face and wall for s c o r i n g or
the area of the shaft where the oil seal seats, wear or excessive wear. If either of the c o n d i t i o n s exist, the
flaking on the area of the shaft where the needle h o u s i n g should be replaced.
bearings travel, and metal d i s t o r t i o n around the
KEYS — Check the keys for any cracks or shear marks
keyway or the retaining ring grooves. If any of these
and replace if necessary.
c o n d i t i o n s exist, the drive shaft s h o u l d be replaced.
P u m p Reassembly
IDLER SHAFT (item 14) — Check the idler shaft for
wear or flaking o n the area of t h e shaft where the Begin the reassembly by placing the s h i m (item 9) in
needle bearings travel and metal d i s t o r t i o n around the p o s i t i o n on the innerface of stator (item 8 ) . A t h i n f i l m
keyway or the retaining ring grooves. If any of these of hydraulic o i l w i l l help m a i n t a i n the location of the
c o n d i t i o n s exist, the idler shaft s h o u l d be replaced. s h i m . If a new s h i m is being i n s t a l l e d , make sure the
s h i m ' s color c o r r e s p o n d s t o the color of the s h i m
GEARS (item 12) — Inspect the gears for any s i g n s of removed d u r i n g d i s a s s e m b l y . Preassemble the idler
galling or metal b u i l d - u p on the side faces of the and drive gear a s s e m b l i e s by installing the keys,
gears as well as o n the o u t s i d e diameter of the t e e t h . gears (item 12) and retaining rings (item 17) o n t o their
If these c o n d i t i o n s exist, the gears must be replaced. respective shafts ( i t e m s 14 and 15).
When replacing gears, always replace both gears as a
set. The drive shaft s h o u l d be i n s t a l l e d . Once in p o s i t i o n ,
introduce the end of the drive shaft into the sleeve
OIL SEAL (item 6) — Check the oil seal rubber for bore and slide the shaft to a p o s i t i o n where the side
wear, cracks, c h i p s or any other c o n d i t i o n that w o u l d of t h e gear is in c o n t a c t w i t h the stator innerface.
cause the seal to lose its sealing a b i l i t y . Snould any
Insert t h e idler gear shaft into its respective bore after
of these c o n d i t i o n s e x i s t , Crown r e c o m m e n d s seal
a l i g n i n g and m e s h i n g the gear teeth properly. Once
replacement. To replace the seal, pry out the o l d seal
s.-a'ts are ir pos t i o n , check to make sure the
being careful not to damage the stator oil seal bore.
s h i m is free of the gear t e e t h . Replace the t w o (2)
Locate and squarely press in the new seal " l i p f i r s t " .
d o w e l pins (item 18) and after a l i g n i n g the scribed
NEEDLE BEARINGS (item 10) — W i t h the use of a match m a r k s , carefully slide the gear h o u s i n g in place
new shaft (idler or drive) or a metal rod g r o u n d to a and install s c r e w s . If for s o m e reason the scribe
dimension of . 5 0 0 0 " / . 4 9 9 7 " in diameter, inserted into marks are not v i s i b l e , a check t o assure proper
the bearing bores, check for excessive bearing to assembly is as f o l l o w s :
shaft clearance in the stator bearings as well as the
gearhousing bearings. A l t h o u g h replacement bearings H o l d the p u m p in a p o s i t i o n where y o u are
are available, Crown r e c o m m e n d s the replacement of viewing the o u t s i d e face of the gear h o u s i n g
the entire stator and (or) gear h o u s i n g because (screw heads s h o u l d be v i s i b l e ) . Rotate the
bearing wear or damage usually d a m a g e s the bearing p u m p to a p o s i t i o n where the idler shaft is
bores. directly below the drive shaft. From that
p o s i t i o n , t h e Vz" NPTF port s h o u l d be on
STATOR (item 8) — Inspect the innerface of the stator your left side.
for signs of s c o r i n g , excessive wear or metal
After y o u are sure of the p o s i t i o n i n g , finger t i g h t e n
build-up. If a slight metal b u i l d - u p is evident, the
the eight (8) a s s e m b l y s c r e w s and check to see that
stator face can be lapped s m o o t h w i t h the use of a
the drive shaft rotates freely. If it d o e s , the screws
solvent soaked crocus c l o t h (280 or 320 grit) placed
can be tightened to a t o r q u e reading of between 8 to
on a flat surface. Care s h o u l d be taken to remove only
10 l b . / f t . (10.8 t o 13.6 N / M ) . Again check to see that
enough material to clean up the b u i l d - u p s . A stator
the shaft turns freely.
having a scored or worn innerface s h o u l d be replaced.

C r o w n 1984 P F - 5 8 7 5 - 2 Printed in U . S . A .

M2.1 - 1 8 - 0 0 2 M2.1 - 1 8 - 0 0 2
 CRQUJh MAINTENANCE

VALVE S P O O L SPRING NOTE

Disassembly Threads should be free of dirt and grease, on
both the screw and valve spool.
Plug all ports and clean the outside of the valve thoroughly
using a suitable solvent. Remove the end cap by remov- Clamp or hold the tang end of the valve spool and insert
ing the two (2) mounting screws that hold it in place. (Refer the screw through the spacer/spring and screw into place,
to Illustration 2-1). To remove the screw on the end of the torquing to 2-3 ft./lbs. (3-4 Nm). After assembly check the
valve spool, clamp or hold the tang end of the valve spool centering spring for proper operation. To do this push down
to keep it from moving and remove the screw. on the screw. This should compress the spring and return
it when released. Apply a medium coat of lubricant over the
NOTE
spring and spacer. Place the end cap over the assembly
This may require heavier than normal forces 5 " : a z- r e mounting holes. Install the mounting screws
since the screw is assembled with thread lock- and torque to 2-3 ft./lbs. (3-4 Nm) and check valve again
ing adhesive. for proper operation.
With the screw removed the spacer, spring and washer can LOAD CHECK SPRING
also be removed.
Disassembly
CAUTION =
e ~ : . 5 :-e r e - - l u g . spring and poppet from the valve
Movement of the valve spool in or out of the valve body (refer to Illustration 2-2). Remove the O-ring from the
body will damage the "0"-rings. hex plug and discard.
Inspect the parts for excessive wear or damage and if NOTE
damaged they should be replaced. If the parts are to be
All " 0 " - r i n g s and back up rings should be
reused, clean and dry them thoroughly using a suitable sol-
replaced as new parts and not reused.
vent making sure to remove any old lubricant from within
the end cap. Inspect the parts for excessive wear or damage arid if
damaged they should be replaced. If the parts are to be
reused, clean and dry them thoroughly using a suitable
solvent.
VALVE BODY

VALVE BODY

^§f- CENTERING
WASHER "^m..^^' SPRING
LOAD CHECK
SPRING
SPACER SCREW
HEX PLUG
JG

MOUNTING
END CAP
SCREW
O-RING

AOX>8 ILLUSTRATION 2-1 A0899 ILLUSTRATION 2-2

Reassembly Reassembly
Install the washer onto the end of the valve spool and in- Insert poppet into the port and center (refer to Illustration
sert the spacer into the spring (refer to Illustration 2-1). 2-2), and then insert spring into the hole in poppet.
Place one drop of thread locking adhesive onto the end of Lubricate the new O-ring with oil and install on the hex plug,
the threads on the screw (excessive thread locking using care not to cut or over stretch the O-ring. Install the
adhesive could hamper proper valve operation). hex plug assembly into the valve body over the poppet and
spring, and torque to 15-20 ft./lbs. (20-27 Nm).

Crown 1989 PF-8444-1 Printed in U.S.A."

M2.3 -18 - 001 M2.3 -18 - 001

 CRQUJh MAINTENANCE

P R E S S U R E BEYOND PORT NOTE

Disassembly All O-rings and back up rings should be re-
placed as new parts and not reused.
Remove the pressure beyond plug assembly from the valve
body. (Refer to Illustration 2-3). Remove the O-rings and To remove the seat, clamp or hold the valve body to keep
back up ring from the pressure beyond plug with a brass it from moving and remove the seat.
tool, using care not to scratch or nick the plug and port.
NOTE
NOTE
This may require heavier than normal forces
All " 0 " - r i n g s and back up rings should be since the seat is assembled with thread locking
replaced as new parts and not reused. adhesive.
Clean and dry the pressure beyond plug thoroughly using Inspect the parts for excessive wear or damage and if
a suitable solvent. damaged they should be replaced. If the parts are to be
reused, clean and dry them thoroughly using a suitable
solvent.
JAM NUT BACK UP
RING

ADJUSTING
O-RING
SCREW

PRESSURE
BEYOND
POPPET
PLUG
VALVE BODY
BACK UP
RING

Aoaoo ILLUSTRATION 2-3 A090! ILLUSTRATION 2-4

Reassembly Reassembly
Lubricate the new O-rings and back up ring with oil. Install Place one drop of thread locking adhesive on the threads
the largest O-ring over the threaded area (refer to Illustra- of the seat (excessive thread locking adhesive could
tion 2-3), using care not to cut or over stretch the O-ring. hamper proper valve operation). Refer to Illustration 2-4.
Install the back up ring into the groove of the plug, and then
NOTE
add the O-ring. Insert the pressure beyond plug assembly
into the port and torque to 60-70 ft./lbs. (81-95 Nm). Threads should be free of dirt and grease, on
both the screw and valve body.
RELIEF VALVE
Clamp or hold valve body and screw seat into place, tor-
Disassembly
quing to 8-10 ft./lbs. (11 -14 Nm). Insert the poppet into the
Remove the hex jam nut from the adjusting screw and set seat and add the spring. Lubricate the new O-ring and back
aside (refer to Illustration 2-4). Loosen the adjusting screw up ring with oil and install them over the groove in the ad-
and remove from the port along with the spring and poppet. justing screw, using care not to cut or over stretch the
Remove the O-ring and back up ring from the adjusting O-ring. Screw the adjusting screw into the port over the
screw and discard. spring and add the jam nut. Tighten the jam nut to lock the
position of the adjusing screw.

Crown 1989 PF-8444-2 Printed in U.S.A. -

M2.3 -18 - 002 M2.3 - 18 - 002

 MAINTENANCE

Relief Valve Adjustment

To adjust relief valve loosen the hex jam nut and using a
screwdriver, turn the adjusting screw to the left. This will
decrease pressure in the valve, while turning the adjusting
screw to the right will increase the pressure in valve. After
proper adjustment is made, tighten the hex jam nut to lock
the position of the adjusting screw.

S P O O L O-RINGS

Disassembly
Remove the end cap assembly as shown in Illustration 2-1
and remove valve spool from the valve body. Use a brass
tool to remove the two (2) O-rings from the valve body and
discard, using care not to scratch or damage the bore.
NOTE
All O-rings and back up rings should be re-
placed as new parts and not reused.

Inspect the valve spool and bore for excessive wear or

damage and if damaged the complete valve should be Aosoa ILLUSTRATION 2-6
replaced. If the valve spool is to be reused, clean and dry
the spool thoroughly using a suitable solvent. Rotate spool by pushing and pulling upward until bottom
edge of spool is even with the top edge of the O-ring groove
Reassembly on the bottom of valve body. Repeat the same procedure
Insert the tang end of the valve spool into the bottom of the for O-ring installation as shown above. After bottom O-ring
valve body until the spool is even with the bottom end of installation push and rotate valve spool until the bottom
the O-ring groove on the top of the valve body. Refer to Il- edge of spool is aligned with the bottom of valve body.
lustration 2-5. Lubricate the new O-rings with oil and insert Reassemble the end cap assembly as shown in Illustration
one (1) into O-ring groove in valve body as shown. 2-1.

VALVE BODY

A0902 ILLUSTRATION 2-5

With a brass tool push or force O-ring i nto groove as shown
in Illustration 2-6.

Crown 1989 PF-8444-3 Primed in U.S.A.-

M2.3 -18 - 003 M2.3 - 18 - 003

 MANIFOLD VALVE

MAIN/AUXILIARY LIFT/LOWER MANIFOLD VALVE

RV1

RV2

SV2

SV3

ILLUSTRATION 1

The main/auxiliary lift/lower manifold assembly is an inte- Component Operation

grated circuit manifold valve consisting of a body, two
adjustable relief valves (RV1 and RV2), two spring loaded RELIEF VALVE (RV1)
normally closed solenoid valves (SV2 and SV3), and the
necessary O-rings and plugs. The body is constructed of This adjustable relief valve is incorporated in the manifold
aluminum, bored to contain interconnected passages for a assembly to prevent component damage by relieving exces-
series parallel circuit. All body ports are tapped with SAE sive oil pressure build up in the main lift circuit. The relief
straight thread "OT ring ports which provide leak proof valve is located in the port marked with the symbol (RV1) of
connections and reduce possible body distortion when in- the manifold block. The relief setting is made by backing-off
stalling and tightening fittings, valves or the plugs. the locking nut and turning the adjusting screw with a blade
screwdriver until the desired load (not to exceed nameplate
rating) can be lifted. Turning the adjusting screw clockwise
will increase (a) the amount of weight the truck will lift (b)
system PSI (c) current draw of lift motor. Turning counter-
clockwise will decrease the above. Refer to Chart 1. Once
adjusted, the locking nut should be tightened.

7438

Crown 1988 PF817Z-1 Rev. 2/04 Printed in U S A

04 REV. 2/04
M2.4-19.0-001 M2.4-19.0-001
 MANIFOLD VALVE

RATED MINIMUM MAXIMUM (t) LOAD

MODELS CAPACITY (*) LIFT LIFT CENTER

30TSPTF 1360 kg (3000 lbs.) 1450 kg (3200 lbs.) 1560 kg (3450 lbs.) 610 mm (24 in.)

* = Refer to identification plate for actual capacity.

t = The load center is the horizontal distance along the forks from the load backrest to the center of gravity of the load. All
trucks must be able to lift this load above free lift height.

CHART 1

RELIEF VALVE (RV2) SOLENOID VALVE (SV2)

This adjustable relief valve is incorporated in the manifold The solenoid valve, located in the port marked SV2, controls
assembly to prevent component damage by relieving exces- the flow of hydraulic oil from the main lift cylinder. The valve
sive oil pressure build up in the auxiliary lift circuit. The relief is two position, coil (electrically) operated, spring loaded with
valve is located in the port marked with the symbol (RV2) of an internal check valve in its static position. When energized,
the manifold block. The relief setting is made by backing-off the spool shifts allowing free flow from the main lift cylinder
the locking nut and turning the adjusting screw with a blade back to the reservoir. Should the solenoid ever have to be
screwdriver until the desired load can be lifted. Turning the removed or replaced, it should be tightened to a torque value
adjusting screw clockwise will increase (a) the amount of of 18.0 - 19.2 Nm (160 to 170 in. lb.).
weight the truck will lift (b) system PSI (c) current draw of lift
motor. Turning counter-clockwise will decrease the above. NOTE
Refer to Chart 1. Once adjusted, the locking nut should be
tightened. Over-torque valve components may cause com-
ponents to malfunction. Follow torque require-
NOTE ments closely.

After relief valves are adjusted to proper capacity, SOLENOID VALVE (SV3)
apply security sealant to the adjusting screw of
the relief valve to hinder tampering. The solenoid valve, located in the port marked SV3, controls
the flow of hydraulic oil from the auxiliary lift cylinder. The valve
When replacing the entire relief valve in the manifold, torque is two position, coil (electrically) operated, spring loaded with
to 20.3 - 23.0 Nm (15 - 17 ft. lbs.) to reduce the possibility of an internal check valve in its static position. When energized,
component damage. Over-torque valve components may the spool shifts allowing free flow from the auxiliary lift cylinder
cause components to malfunction. Follow torque require- back to the reservoir. Should the solenoid ever have to be
ments closely. removed or replaced, it should be tightened to a torque value
of 18.0 -19.2 Nm (160 to 170 in. lb.).

Crown 1988 P F 8 1 7 2 - 2 Rev. 2/04 Printed in U.S.A.

04 R E V . 2/04
M2.4-19.0-002 M2.4-19.0-002
 MANIFOLD VALVE

Troubleshooting Procedure

Before beginning any repair or disassembly of the valve When it has been determined that one or more of the
assembly perform the following steps to prevent wasted components are faulty, the following procedure should be
time, additional damage or recurring problems. followed in trying to isolate or pinpoint the problem valve.
Begin by inspecting the body for fresh hydraulic oil around
1. Obtain as much factual information as possible - component valves, plugs and fittings. If any leaks are found
discuss malfunction with truck's operator. the components should be removed and its thread sealing
"O" ring replaced. Next, inspect the solenoid valve (SV1 and
2. Operate truck, all functions - verify malfunction. SV2) for any visual signs of damage. If the coil feels hot, the
coil is shorted and should be replaced. Coils can be faulty
3. Know the truck's hydraulic system - refer to appropri- even if no heat is detected. Overtightening the valve can
ate hydraulic schematic. also keep the valve from shifting correctly. The torque
requirements for the solenoid valve is 18.0 -19.2 Nm (160
4. Determine symptom, possible cause and solutions. to 170 in. lbs.) (max.). The relief valves (RV1 and RV2)
should be checked next. If the proper system pressure can
(Refer to Illustration 1 and Charts 1 and 2) not be obtained, the pressure spring in the valve could be
broke and the valve should be replaced.
Before removal or disassembly of the valve assembly, make
sure the valve is clean and free of any contaminates. Also,
have a means of containing and controlling any hydraulic oil
that may escape.

TROUBLESHOOTING CHART

(REFER TO ILLUSTRATION 1)

TROUBLES PROBABLE CAUSE REMEDY

1. Oil present around manifold. A. Defective " 0 " rings on valves, A. Replace " 0 " rings and "O" rings
fittings or plugs. on hydraulic fittings.

2. Main lift cylinders will not raise A. Relief valve not adjusted cor- A. Readjust relief valve in accor-
capacity load. rectly. dance with Chart 1.

B. Solenoid valve stuck in open B. Replace valve [*].

(free flow) position.

C. Manual lowering valve left open. C. Close valve.

3. ( t ) Operator compartment drifts A. Defective " 0 " rings or back-up A. Replace " 0 " rings and back-up
down. rings. rings [*].

B. Dirt caught in seat on solenoid B. Actuate to flush out dirt. If dirt

valve. continues, replace valve [*].

C. Manual lowering valve open C. Close or replace " 0 " rings and
slightly or leaking. back-up rings [*].

4. Operator compartment will not A. Solenoid coil failure. A. Replace solenoid coil.
lower.
B. Electrical malfunction, switch B. Refer to "Electrical" Section.
malfunction, etc...

[*] = Torque required is 18.0 - 19.2 Nm (160 to 170 in. lbs.) (max.)

(t) = In excess of drift test.

CHART 2

Crown 1988 PF8172-3 Rev. Z'M Printed in U S A

04 REV. 2/04
M2.4-19.0-003 M2.4-19.0-003
 CRQUJh MAINTENANCE

C0253 -LUSTRATION 2.4-1

T R A V E R S E MANIFOLD VALVE SOLENOID VALVE (SV4) (SV5)
The traverse manifold valve asserri!) s a- -tegrated cir- These solenoid valves located in the ports marked with the
cuit manifold valve consisting of a body, two single pilot symbols SV4 and SV5 of the manifold block, control
check valves (CV), (3) directional two position solenoid hydraulic oil flow to the fork extend/retract cylinders. These
valves (SV4, SV5, SV10), a shuttle valve and the necessary valves are two position, coil (electrically) operated and
o-rings, plugs, etc. The valve body or block is constructed spring loaded. When energized, the spool shifts allowing
of aluminum, bored to contain interconnected passages for flow from the traverse motor to the fork cylinders. Should
a series parallel circuit. All body ports are tapped with SAE the solenoid ever have to be removed or replaced, it should
straight thread o-ring ports which provide leakproof con- be tightened to a torque value of 160 to 170 in./lb.
nections and prevent possible body distortion when i nsta!-
NOTE
ling and tightening fittings, valves or plugs.
Over-torqued valve components may cause com-
Component Operation
ponents to m a l f u n c t i o n . Follow torque re-
SINGLE PILOT CHECK VALVES (CV) quirements closely.
The single pilot check valves located in the ports marked
with the symbol CV of the manifold block. When hydraulic
pressure is applied to the hydraulic motor, for traverse,
these cartridge type valves work together to prevent the
hydraulic motor from "free-wheeling" and/or coasting
when hydraulic pressure is removed. "Crack" pressure of
this valve is 25 PSI.

Crown 1988 PF-8182-1 Printed in U.S.A.'

M2.4 - 19 - 100 M2.4-19 - 100

 MAINTENANCE

SOLENOID VALVE (SV10)

This solenoid valve, located in the port marked with the
symbol SV10 of the manifold block, controls the direction
of fork extension cylinders. This valve is commonly referred
to as the "Traverse Flip-Flop" solenoid valve. This valve
is two position, coil (electrically) operated and spring
loaded. When energized, the spool shifts reversing the
direction of travel of the fork extension cylinders. Should
the solenoid ever have to be removed or replaced, it should
be tightened to a torque value of 160 to 170 in./lb.

NOTE
Over-torqued valve components may cause components
to malfunction. Follow torque requirements closely.
SHUTTLE VALVE

C0254 ILLUSTRATION 2.4-2

The shuttle valve is a simple ball and seat valve. It is
designed to allow hydraulic pressure to the accumulator
during traverse that provides for smooth transition from
traverse to fork extend or retract. When SV4 and SV5 are
energized or de-energized the accumulator provides a
cushion effect at transition.

Crown 1988 PF-8182-2 Printed in U.S.A.'

M2.4- 19 - 101 M2.4- 19 - 101

 enaiun MAINTENANCE

SOLENOID VALVE (SV10)

This solenoid valve, located in the port marked with the
symbol SV10 of the manifold block, controls the direction
of fork extension cylinders. This valve is commonly referred
to as the "Traverse Flip-Flop" solenoid valve. This valve
is two position, coil (electrically) operated and spring
loaded. When energized, the spool shifts reversing the
direction of travel of the fork extension cylinders. Should
the solenoid ever have to be removed or replaced, it should
be tightened to a torque value of 160 to 170 in./lb.

NOTE
Over-torqued valve components may cause components
to malfunction. Follow torque requirements closely.
SHUTTLE VALVE

CO2SA ILLUSTRATION 2.4-2

The shuttle valve is a simple ball and seat valve. It is

designed to allow hydraulic pressure to the accumulator
during traverse that provides for smooth transition from
traverse to fork extend or retract. When SV4 and SV5 are
energized or de-energized the accumulator provides a
cushion effect at transition.

Crown 1988 PF-8182-2 Printed in U.S.A."

M2.4 - 19 - 101 M2.4- 19 - 101

 CRQUJh MAINTENANCE

PIVOT MANIFOLD VALVE

V2 V1
SV11

2696S
ILLUSTRATION 2.4-1

The pivot manifold assembly is an integrated circuit manifold side opens the circuit. This allows the oil from the
valve consisting of a body, (2) preset cross-over relief valves opposite pivot cylinder to return to the reservoir. 'Crack"
(RV), (2) counterbalance valves (CBV), a shuttle valve, a pressure of this valve is 25 PSI (172.3 kPa).
spring loaded normally closed solenoid valve (SV11) and the
necessary "O" rings and plugs. The aluminum body contains SHUTTLE VALVE
interconnected passages for a series parallel circuit. All ports
are SAE straight thread " 0 " ring ports which provide leak The shuttle valve is a simple ball and seat valve. It is
proof connections while preventing possible body distortion designed to allow hydraulic oil to counteract the spring force
when installing and tightening fittings, valves or plugs. of the pivot lock cylinder while rotating in either direction.
When the pivot circuit is not energized, the oil in the pivot lock
Component Operation circuit returns to the reservoir and the spring resets the pivot
lock.
RELIEF VALVE (RV)
SOLENOID VALVE (SV11)
The cross-over relief valves incorporated in this manifold are
designed to prevent pivot cylinder damage by relieving This solenoid valve, located in the port marked with the
excessive oil pressure build up in the pivot circuit. The relief symbol SV11 of the manifold block, allows the forks to pivot
valves are located in the sides of the manifold. Both relief only when the forks are retracted. This valve is two position,
valve ports are marked with the symbol (RV). These relief coil (electrically) operated and spring loaded. When ener-
valves are factory set at 1500 PSI (10.3 MPa) and under gized, the spool shifts allowing oil flow to the pivot cylinders.
normal conditions should not need adjustments. Should the solenoid ever be removed or replaced, it should
be tightened to a torque value of 160 to 170 in./lb. (18.0-19.2
COUNTERBALANCE VALVE (CBV) Nm).

The counterbalance valves are located in the sides of the NOTE

manifold (marked CBV). These valves check the return of oil
back to the reservoir. When hydraulic pressure is applied to Over-torque valve components may cause com-
a given pivot cylinder, an internal pilot line from the pressur- ponents to malfunction. Follow torque require-
ments closely

Crown 1988 PF-8173-1 Rev. 1/94 Printed in U.S.A.

01 REV. 1/94
M2.4 - 19 - 200 M2.4- 1 9 - 2 0 0
 CROUJh MAINTENANCE

Troubleshooting Procedure
Before beginning any repair or disassembly of the valve When it has been determined that one or more of the com-
assembly perform the following steps to prevent wasted ponents are faulty, the following procedure should be
time, additional damage or recurring problems. followed in trying to isolate or pinpoint the problem valve.
Begin by inspecting the body for fresh hydraulic oil around
1. Obtain as much factual information as possible —
component valves, plugs and fittings. If any leaks are found
discuss malfunction with truck's operator.
the components should be removed and its thread sealing
2. Operate truck, all functions — verify malfunction. " O " ring replaced. Next, inspect the relief valves. If the pro-
per system pressure can not be obtained, the pressure
3. Know the truck's hydraulic system — refer to ap-
spring in the valve could be broke and the valve should be
propriate hydraulic schematic.
replaced. When the counterbalance valves are not working
4. Determine symptom, possible cause and solutions. properly, they must be replaced.

(Refer to illustration 2.4-1 and chart 2.4-1)

Before removal or disassembly of the valve assembly,

make sure the valve is clean and free of any contaminates.
Also, have a means of containing and controlling any
hydraulic oil that may escape.

TROUBLESHOOTING CHART
(REFER TO ILLUSTRATION 2.4-1)

TROUBLES PROBABLE CAUSE REMEDY

1. Oil present around manifold A. Defective " 0 " rings on valves, A. Replace " 0 " rings and " 0 " •
fittings or plugs. rings on hydraulic fittings.
2. Fork carriage will not pivot but A. Relief valve stuck open (free A. Replace valve (*).
pivot lock cylinder unlocks. flow) position.
B. Counterbalance valve not B. Replace valve (*).
working.
3. Fork carriage will not pivot and A. Shuttle valve ball not seated. A. Actuate to flush out dirt.
pivot lock cylinder will not unlock.
4. Oil leaking from pivot cylinder A. Relief valve on pressurized side
breather. stuck closed. A. Replace relief valve (*).
B. Worn cylinder packing. B. Rebuild cylinder. Refer to
"Cylinder" section.
5. Forks will not pivot left or right. A. Solenoid valve (SV11) not func- A. Actuate to flush out dirt.
tioning properly. B. Check solenoid coil.
C. Replace solenoid. (*)
6. Forks pivot while forks are A. Solenoid valve (SV11) not func- A. Actuate to flush out dirt.
extended. tioning properly. B. Check solenoid coil.
C. Replace solenoid. (*)

[*] = Torque required is 160 to 170 inch lbs. (max.)

CHART 2.4-1

Crown 1988 PF-8173-2 Printed in U.S.A.'

M2.4 - 19 - 201 M2.4 - 19 - 201

 MAINTENANCE

C0S57 ILLUSTRATION 2.4-1

F O R K — F L O W DIVIDER MANIFOLD VALVE

The fork-flow divider manifold assembly is an integrated SINGLE PILOT CHECK VALVE (PCV)
circuit manifold valve consisting of a body, a flow divider
The single pilot check valve, located in the port marked
valve (FDV), single pivot check valves (PCV) and the
PCV, is designed to provide a hydraulic lock to the fork
necessary " O " rings and plugs. The aluminum body con-
cylinder not allowing fork drift. A set screw with an orifice
tains interconnected passages for a series parallel circuit.
is also in this port that meters the oil flow to the pilot check
All ports areSAE straight thread " O " ring ports which pro-
valve to eliminate charter in this circuit. This cartridge valve
vide leakproof connections while preventing possible body
is not adjustable. When replacing the valve in the manifold,
distortion when installing and tightening fittings, valves or
torque to 160 -170 in./lb.
plugs.

Component Operation
FLOW DIVIDER VALVE (FDV)
The flow divider valve, located in the port marked FDV, is
designed to maintain synchronization of the fork cylinders
during extending or retracting. This cartridge valve is not
adjustable. When replacing the valve in the manifold,
torque to 160 -170 in./lb.

Crown 1988 PF-8176 Printed in U.S.A.*

M2.4 - 19 - 300 M2.4 - 19 - 300

 CROUJh MAINTENANCE

BRAKE MANIFOLD VALVE

CI
I
I
T *-

FN
,-4

C2

A ACC
fiva SV9

,
'T>*--.r\?:v:;'i>.-.« >

m A— -CV

2697S
ILLUSTRATION 2.4-1

The brake manifold assembly is an integrated circuit mani- CHECK VALVE (CV)
fold valve consisting of a body, an adjustable relief valve
(RV3), three spring loaded normally open solenoid valves The check valve is located in the upper port of the manifold
(SV7, SV8, SV9), one spring loaded normally closed sole- block marked with the symbol (CV). It prevents the back flow
noid valve (SV6), a check valve (CV) and the necessary "O" of hydraulic oil from the brake cylinders, from reentering the
rings, plugs, etc. The body is constructed of aluminum, bored de-energized pump and returning to the reservoir via the
to contain interconnected passages for a series parallel suction line.
circuit. All body ports are tapped with SAE straight thread "O"
ring ports which provide leak proof connections and reduce ORIFICE
possible body distortion when installing and tightening fit-
tings, valves or plugs. The orifice is located in the port of the manifold block marked
with the symbol (C2). It restricts the flow of hydraulic oil from
Component Operation the accumulator allowing for smoother brake release.

RELIEF VALVE (RV3) SOLENOID VALVE i,3V6)

The relief valve is incorporated in the manifold assembly to The solenoid valve (SV6), located in the port of the manifold
prevent component damage by relieving excessive oil pres- marked with the symbol (SV6) is a normally closed valve. It
sure build up in the brake circuit. The relief valve is located controls the releasing of the brake cylinders. The valve is a
in the port marked with the symbol (RV3) of the manifold spring loaded, two positioned, coil (electrically) operated
block. This relief valve is pre-set at 2000 PSI (13.8 MPa). valve with an internal check valve in its static (home) posi-
Under normal conditions this valve should not require adjust- tion. When energized, the spool shifts allowing hydraulic
ment. When replacing the entire relief valve in the manifold, pressure to counteract spring pressure which releases the
torque to 15 - 17 ft./lbs. (20.3 - 23.0 Nm) to reduce the brakes. The solenoid valve (SV6) works in conjunction with
possibility of component damage. Over-torque valve com- (SV7) solenoid valve.
ponents may cause components to malfunction. Follow
torque requirements closely.

Crown 1988 PF-8177-1 Rev. 1/94 Printed in U.S.A.

01 REV. 1/94
M2.4 - 19 - 400 M2.4- 1 9 - 4 0 0
 CRQUJh MAINTENANCE

SOLENOID VALVE (SV7) Troubleshooting Procedure

The solenoid valve (SV7), located in the port of the manifold Before beginning any repair or disassembly of the valve
marked with the symbol (SV7) is a normally open valve. This assembly perform the following steps to prevent wasted
solenoid keeps the spring pressure from applying the brakes. time, additional damage or recurring problems.
The valve is a spring loaded, two position, coil (electrically)
operated valve with an internal check valve in its energized 1 .Obtain as much factual information as possible- • discuss
(applied) position. When energized, the spool shifts prevent- malfunction with truck's operator.
ing hydraulic oil from returning to the reservoir, maintaining
the release of the brakes. 2.Operate truck, all functions—verify malfunction.

SOLENOID VALVE (SV8) 3.Know the truck's hydraulic system -refer to appropriate
hydraulic schematic.
The solenoid valve (SV8), located in the port of the manifold
block marked with the symbol (SV8) is a normally open 4.Determine symptom, possible cause & solutions.
valve. This solenoid is used to keep the brake circuit charged
when the brakes are being used frequently without working (Refer to Illustration 2.4-1 and Chart 2.4-1)
the accessory functions. This valve is two position, coil
(electrically) operated and spring loaded. When energized, Before removal or disassembly of the valve assembly, make
the spool shifts allowing the brake circuit to recharge without sure the valve is clean and free of any contaminates. Also,
the need to operate an accessory function . have a means of containing and controlling any hydraulic oil
that may escape.
SOLENOID VALVE (SV9)
When it has been determined that one or more of the
The solenoid valve (SV9), is located in the port of the components are faulty, the following procedure should be
manifold block marked with the symbol (SV9) is a normally followed in trying to isolate or pinpoint the problem valve.
open valve. This solenoid keeps the drive unit brakes re- Begin by inspecting the body for fresh hydraulic oil around
leased to soften braking when truck travel speed is less 2.4 component valves, plugs and fittings. If any leaks are found
MPH (3.8 Kph) and the brakes are applied. The valve is a the components should be removed and its thread sealing
spring loaded, two position, coil (electrically) operated valve "O" ring replaced. Next, inspect the solenoid valve for any
with an internal check valve in its energized (applied) posi- visual signs of damage. If the coil feels hot, the coil is shorted
tion. When energized, the spool shifts not allowing hydraulic and should be replaced. Coils can be faulty even if no heat
oil from returning to the reservoir, maintaining the release of is detected. Overtightening the valve can also keep the valve
the brakes. from shifting correctly. The torque requirements for the
solenoid valve is 160 to 170 in./lbs. (18.0-19.2 Nm) (max.).
The check valve should be checked next. If the brakes
accumulator will not release the brakes when the pump is not
energized, the check valve could have a broken spring or
chipped seat. The check valve should be replaced.

TROUBLES PROBABLE CAUSE REMEDY

1. Oil present around manifold. A. Defective "O" rings on valves, A. Replace "O" rings and "O"
fittings or plugs. rings on hydraulic fittings.

2. Brakes will not release. A. Solenoid coil failure (SV6 or SV7). A. Replace solenoid coil(s).
B. Orifice plugged. B. Remove and clean.

3. Accumulator loses charge. A. Dirt caught in check valve seat of A. Actuate to flush out dirt. Replace
SV8. if necessary.
B. Defective "Of rings or back-up B. Replace "O" ring and back-up
rings of SV8. ring [*].

[*] = Torque required is 160 - 170 inch lbs. (18.0 -19.2 Nm) (max.).

CHART 2.4-1
Crown 1988 PF-8177-2 Printed in U.S.A.

01 REV. 1/94
M2.4- 1 9 - 4 0 1 M2.4 - 1 9 - 4 0 1
 MAINTENANCE

TRAVERSE CUSHION
I PFR1

PFR2

C0255 ILLUSTRATION 2.4-1

T R A V E R S E CUSHION VALVE
r
The traverse cushion manifold assembly is an integrated : - a . e ' 3 e ~ : : : o i l flow to the reservoir, slowing the traverse
circuit manifold valve consisting of a body, two priority flow speed before contacting stops. The remaining oil is
regulating valves (PFR1 & PFR2), a check valve (CV), a diverted through PFR2 valve to allow for the proper
directional two position solenoid valve (SV12) and the traverse cushion. Should the solenoid valve ever be
necessary o-rings, plugs, etc. The valve body or block is removed or replaced, it should be tightened to a torque
constructed of aluminum, bored tc contain interconnected value of 160 to 170 in./lb.
passages for a series parallel circuit. All body ports are
NOTE
tapped with SAE straight thread o-ring ports which provide
leakproof connections and reduce possible body distortion Over-torqued valve components may cause com-
when installing and tightening fittings, valves or plugs. ponents to malfunction. Follow torque requirements
closely.
Component Operation
PRIORITY FLOW REGULATING VALVE (PFR1)
CHECK VALVE (CV)
The priority flow regulating valve, located in the port of the
The check valve is located in the port of the manifold block
manifold block marked with the symbol (PFR1). This valve
marked with the symbol (CV). It prevents back flow of
is adjusted to obtain a smooth pivot operation. The pivot
hydraulic oil through PFR2 when traverse is operating at
operation, from stop to stop or a full 180°, should be 7.2
maximum speed.
to 8.8 seconds. To make this adjustment, back-off the lock-
SOLENOID VALVE (SV12) ing nut and turn the adjusting screw with the proper size
hex key until the proper setting is obtained. Turn the
The solenoid valve, located in the port of the manifold block
adjusting screw " i n " (clockwise) to obtain a faster pivot
marked with the symbol (SV12), diverts the flow of
speed. Turn the adjusting screw "out" (counter-clockwise)
hydraulic oil to the PFR2 valve to obtain a cushion at the
to obtain a slower pivot speed. When properly adjusted, the
end of traverse. The valve is two position, coil (electrically)
locking nut should be tightened.
operated and spring loaded. When energized, the spool
shifts allowing maximum traverse speed. When de-
energized, the spool shifts diverting a portion of the

Crown 1988 PF-8178-1 Primed in U.S.A.-

M2.4 - 19 - 500 M2.4 - 19 - 500

 CRQUJh MAINTENANCE

PRIORITY FLOW REGULATING VALVE (PFR2)

The priority flow regulating valve, located in the port of the Before removal or disassembly of the valve assembly,
manifold block marked with the symbol (PFR2). This valve make sure the valve is clean and free of any contaminates.
is adjusted to obtain a smooth cushion effect at the end of Also, have a means of containing and controlling any
the traverse function completely to the left or right. This hydraulic o I that may escape.
valve restricts the flow of oil to the traverse control valve.
When it has been determined that one or more of the com-
The greater the restriction, the slower the speed of
ponents are faulty, the following procedure should be
traverse. The traverse function, from stop to stop, should
followed in trying to isolate or pinpoint the problem valve.
be: 52" width platform — 5.5 to 6.8 seconds, 58" width
Begin by inspecting the body for fresh hydraulic oil around
platform — 6.2 to 7.5 seconds. To make this adjustment,
component valves, plugs and fittings. If any leaks are found
back-off the locking nut and turn the adjusting screw with
the components should be removed and its thread sealing
the proper size hex key until the proper setting is obtained.
o-ring replaced. Next, inspect the solenoid valve (SV12) for
Turn the adjusting screw " i n " (clockwise) to obtain a faster
any visual signs of damage. If the coil feels hot, the coil is
traverse speed. Turn the adjust screw "out"(counter-
shorted and should be replaced. Coils can be faulty even
clockwise) to obtain a slower traverse speed. When pro-
if no heat is detected. Overtightening the valve can also
perly adjusted, the locking nut should be tightened.
keep the valve from shifting correctly. The torque re-
NOTE quirements for the solenoid valve is 160 to 170 in./lbs.
(max.). The check valve (CV) should be checked next. If
The Fork extend function should be at a speed of
not operating properly, it could have a broken spring or
2.0 to 3.0 inches per second.
chipped seat. The check valve should be replaced. Next,
Troubleshooting Procedure inspect the priority flow regulating valves (PFR1 & PFR2).
If the proper function speed of pivot and traverse can not
Before beginning any repair or disassembly of the valve
be obtained, internal damage may be present and the valve
assembly perform the following steps to prevent wasted
should be replaced.
time, additional damage or recurring problems.
1. Obtain as much factual information as possible —
discuss malfunction with truck's operator.
2. Operate truck, all functions — verify malfunction.
3. Know the truck's hydraulic system — refer to ap-
propriate hydraulic schematic.
4. Determine symptom, possible cause & solutions.

(Refer to Illustration 2.4-1)

Crown 1988 PF-8178-2 Primed in U.S.A.*

M2.4 -19 - 501 M2.4 - 19 - 501

 cnoiun MAINTENANCE

SERVO LIFT/LOWER CONTROL VALVE

10

2804S
ILLUSTRATION 2.5-1
Description eads from LVDT at TB204. Note lead locations for future
-eference at installation. Move valve assembly to a clean,
The- servo lift/lower control valve is a single spool valve. well lighted work area i further disassembly is required.
Spool movement is controlled by an electrical servo - a t e r
mounted to the valve body. An LVDT (linear variable z----- Disassembly
ential transformer) is mounted to the opposte era r the
valve body and electrically monitors the spool position. The (Refer to Illustration 2.5-1.)
valve assembly is located on the right side of the truck. The Thoroughly clean the exterior of the valve before beginning
right hand cover must be removed to gain access for r a i n - disassembly procedures. Inspect parts as they are disas-
tenance and inspection. Spool movement is proportional to sembled for burrs, nicks, wear and damage.
raise/lower control lever movement by the operator. The
electrical signal generated by control! lever movement is 1. Turn item 12, LVDT assembly, counter-clockwise care
sent to the truck's processors. The LVDT sends a signal to fully from mounting bracket, item 1 1 . Remove spacer,
the processors. These signals determine the signal to be item 14, and spring washers, item 5 from mounting
sent to the servo motor. bracket. Record spring washer position and quantity for
reference at assembly.
Removal
2. Remove LVDT core, item 15, and stud, item 13, from end
Be sure the operator compartment and forks are lowered of valve spool. Do not scratch or mark core during
completely. Turn key switch to the "OFF' position and disassembly.
disconnect battery. Remove the cover from the right hand
side of the power unit. Disconnect the four hydraulic lines 3. Remove the four screws, item 2, holding the two
from valve. Absorb any hydraulic oil that may drain from lines spacers, items 3 & 7, together. A 7/16" hex key is
at this time. Remove the three bolts securing the valve required to remove item 2.
assembly to the power unit. Disconnect the four electrical

Crown 1S85 PF-7076-1 Rev. 1/94 Printed in U.S.A.

01 R E V . 1/94
M2.5- 1 8 - 1 0 0 M2.5-18-100
 crawn MAINTENANCE

4. A screwdriver slot in the end of the motor must be used A. Remove the 5/16" screw from the end of the valve
to turn the threaded motor shaft out of the spool. spool. A 1/4" hex key is required to remove screw.
Also remove the steel washer and spacer.
5. Remove spring washers, item 5, from spacer, item 3.
Record spring washer position and quantity for B. Remove the four 1/4" screws securing the two wiper
reference at assembly. retainer brackets to the valve body. A 3/16" hex key
is required to remove screws. Take care not to
6. Remove four screws, item 4. securing spacer, item 3, to damage or misplace the wiper rings before assem-
motor, item 1. Remove two screws, item 6, securing bly into the servo control valve assembly.
spacer, item 7, to valve, item 9. A 3/16" hex key is
required to remove item 6. C. Install a wiper ring into motor spacer, item 7, and the
other wiper ring into bracket, item 1 1 . Refer to
7. Remove roll-pin, item 10, from valve spool. Support the llustration 2.5-1. The wiper rings must be installed in
back side of spool while removing roll-pin with a 5/16" the same relative position in relation to the valve.
punch. Remove two screws, item 6, securing bracket,
item 11, to valve. A 3/16" hex key is required to remove NOTE
item 6.
Excessive movement of valve spool during dis-
A thorough inspection for burrs, nicks, signs of wear and assembly or assembly can damage internal quad
damage should be conducted of all parts at this time. rings in valve.

Reassembly 2. Install wiper ring properly into adaptor bracket. Attach

adapter to end of valve having the "cross hole" in the
1. If a valve is being replaced, partial valve disassembly will spool. Apply thread locking adhesive (061004-012) to
be required before assembled into the servo control the threads of the two mounting bolts before installing
valve assembly. Refer to Illustration 2.5-2 & 2.5-3.

Crown 1985 P F - 7 0 7 6 - 2 Rev. 1/94 Printed n U . S J

01 R E V . 1/94
M2.5-18-101 M 2 . 5 - 18-10-
 CRQUJh MAINTENANCE

MOTOR SPACER (7)

VALVE BODY (9) ROLL PIN (10)
SERVO MOTOR 0) j BUSH1NQ (8)

SPACER (3) ADAPTOR BRACKET (11) \ SPACER (14)

LVDT (12)

VALVE SPOOL (?) ,, = = F . N 3

E S T I C (13)

SPRING WASHERS (5) Q U A D RING SPAING WASHERS (5) LVDT CORE (15)

2806S
ILLUSTRATION 2.5-3

NOTE 5. Press "DU" bushing into motor spacer until it is flush or

just sightly below pilot surface in motor spacer. Refer to
Inspect all parts. Make sure all burrs are removed Illustration 2.5-5.
and mating surfaces are flat before assembly.
" D U " BUSHING
3. Align hole in spool with slot in adapter. Support the back
side of the spool and carefully press in roll-pin until it is
I —•—
approximately .20 in.(5mm) above slot surface. Referto
Illustration 2.5-4. Be sure spool can be moved back &
forth with fingers easily. !
k
r
S:

r ;

4. Retap the 5716-18 thread in the opposite end of the spool v — i

with a "bottoming'' tap to a minimum depth of .88 in.
(22mm). Clean spool thoroughly to remove any metal MOTOR SPACER
chips, etc.
ILLUSTRATION 2.5-5
R O L L PIN
6. Install motor spacer to valve body. Be sure wiper ring
is installed properly into motor spacer before mounting.
Apply thread locking adhesive to the two mounting bolts
and install. Make sure all mating surfaces are flat and
free of any burrs, etc. Torque the two mounting bolts to
40 in./lbs., to 60 in/ibs., to 80 in./lbs.(4.5 to, 6.8 to,
9.0Nm) alternating back and forth. Be sure spool can be
moved back & forth with fingers easily after mounting
bolts have been torqued properly.

7. Install spacer to servo motor base. Apply thread

locking adhesive to the four mounting screws and install.
Be sure all mating surfaces are flat and free of any burrs,
ADAPTOR BRACKET
etc.
2807S
ILLUSTRATION 2.5-4

Crown 19S5 PF-7076-3 Rev. 1/94 Printed in U.S.A.

01 R E V . 1/94
M2.5- 1 8 - 1 0 2 M2.5-18-102
 cnown MAINTENANCE
SPRING WASHER

SCREWDRIVER
SLOT

2809s ILLUSTRATION 2.5-6

8. Apply thread tapping fluid to the motor shaft thread. Run 12. Apply thread locking adhesive to threads of stud and
a 5/16-18 thread die the full length of threads to clean up- install to other end of spool. Install LVDT core to end of
any imperfections to the motor shaft threads. Clean stud. Wipe off any excess thread locking adhesive from
motor shaft threads thoroughly and apply a generous- stud and LVDT core. Be sure core is not damaged in
amount of "graphite" lubricant (063002-021 )to the mo- any way.
tor shaft threads and the 5/16-18 threads in the end of
the valve spool. 13. Install five spring washers and spacer into adaptor
bracket. Refer to Illustration 2.5-7 for exact position.
9. Install 5 or 6 spring washers, (6 preferred) into spacer
that is mounted to servo motor. Refer to Illustration 2.5-
6 for proper spring position. A light film of grease may be
applied to spring washers to " e p retain them during
assembly.

10. Align threads of motor to the threads in end of valve

spool and use blade screwdriver in slot of motor shaft to
turn motor shaft to engage threads of spool. The spool
may shift during this operation. Turn motor shaft just
enough to bring the spacer blocks into contact with one
another.

11. Align spacers. Apply thread locking adhesive to the four

bolts securing spacers and install properly. Turn motor
shaft with blade screwdriver until roll pin is centered in
slot of bracket. Be sure no tight spots exist when turning
motor shaft. Motor shaft should turn free and easy; if any
binding is present it must be eliminated before any ILLUSTRATION 2.5-7
further assembly.

Crown 1985 PF-7076-4 Rev. 1/94 Printed in U . S . A

01 R E V . 1/94
M 2 . 5 - 1 8 - 103 M2.5-18-103
 MAINTENANCE

14. Apply thread locking adhesive to adaptor bracket and the motor. Unsolder the brush pigtail from the bottom of the
screw LVDTonto bracket until seated properly on bracket clip. Remove brush. Check brush spring for deformation,
shoulder. discoloration, or any other signs that appear abnormal.
Replace if nessary. Position replacement brush with the
After completely assembled the spool travel resistance must pigtail routed over the top of the spring down into the base of
draw less than 1 amp. To center valve the distance from the the clip. Solder pigtail into base of clip. Be sure spring
edge of roll pin to the face of adaptor b racket shouid be .641 position is maintained. The base of the clip is bent inward
in.(16mm) + .056 in.(1.4mm). Refer to Illustration 2.5-8. slightly to allow for proper brush movement during motor
operation. The clip must be straightened in order to remove
+ .056 the clip from brush holder. Compress brush into holder and
.641 position brush assembly into motor. The soldered end of clip
should be installed pointing down into the motor. Install end
ROLL PIN bracket containing the assorted washers on to the end of
motor and secure with the two tie bolts. Be sure the Red dot
is in the same relative position to allow for proper motor
rotation.

NEW BRUSH LENGTH BRUSH NEEDS REPLACED

7/16"- •5/16"

ADAPTOR BRACKET

HOLDER
2811S ILLUSTRATION 2.5-8

Servo Motor Brush Replacement

PIGTAIL OVER
(Refer to Illustration 2.5-9)
TOP OF SPRING

When motor brushes reach an overall length of 5/16"(.3l2

in.[8mm]), both brushes should be replaced. The four screws CLIP SPRING
securing the spacer blocks together must be removed. Use
a blade screwdriver and turn the motor shaft out of the end
of the valve spool. Remove the four screws securing the
spacer block to the motor base. Use a "Phillips" screwdriver
and remove the two "tie" bolts from motor. Mark the motor
yoke and magnet assembly showing the relative position of CLIP BENT
TOWARD BRUSH
the Red dot on end bracket. This information is necessary at
assembly. The end bracket must be installed in the same BRUSH
position in order to keep motor rotation direction from chang-
ing. The Red dot is the positive ( + ) lead connection indicator. 2S12S ILLUSTRATION 2.5-9
Lift the end bracket from motor assembly. Be sure the
assortment of washers between armature and end bracket
are accounted for. The number and position of a washers
must be maintained to obtain proper motor operation. The
brush assembly will remain in the motor after the end bracket
has been removed. Carefully lift the brush assembly out of

Crown 1985 P F - 7 0 7 6 - 5 Rev. 1/94 Prinled in U.S.A.

01 R E V . 1/94
M2.5- 1 8 - 104 M2.5 - 1 8 - 1 0 4
 <2j\awn MAINTENANCE

PIVOT, TRAVERSE/FORK CYLINDER VALVE ASSEMBLY

The pivot and traverse/fork cylinder valves are mechani- 6. Tighten locknuts to secure adjustment.
cally connected to the corresponding control lever of the
Check adjustment of switches.
left hand control assembly. These valves are spring
centered with ports closed. Switches, monitored by the Pivot Command Switch (PTS)
platform electronics box, utilize cams that are part of the
Make certain switch roller is centered in indent of cam
interconnecting linkage to actuate. When actuated the
before adjusting.
electronics boxes start the accessory pump motor.
Hydraulic flow is then controlled by movement of the valve 1. Disconnect battery and chock wheels.
spools. The accessory pump and motor should start before
2. Remove cover behind left hand control assembly.
the valve ports open. If the valve port opens before the
pump starts, the corresponding function will tend to drift 3. Loosen switch mounting screws slightly, so switch can
and then " j e r k " when the pump does start. be moved but is still held in place.
ADJUSTMENTS 4. Pivot switch towards cam until switch actuates,
signified by a " c l i c k " sound. Move switch back until
Cams
switch contacts reset, again signified by a "click"
1. Disconnect battery and chock wheels. sound.
2. Remove cover behind left hand control assembly. 5. Tighten mounting screws.
3. Remove cover from platform wall, under left hand con- 6. Install cover, remove wheel chocks and connect
trol assembly. battery.
4. Loosen locknuts on both ends of adjusting rod be- When adjusted properly, the switch will actuate before the
tween valve and cam assembly. valve spool moves .030" (0.7mm). This will start the ac-
cessory pump and motor before the valve ports open.
5. Center roller of switch PTS in detent of cam. Rollers
of traverse switches, TVSL and TVSR, must be an Traverse Command Switches (TVSL & TVSR)
equal distance from their corresponding cam lobe as
Make certain switch rollers are positioned properly on cam
shown in Illustration 2.5-1.
assembly before adjusting.
_
.5 =
1. Disconnect battery and chock wheels.
2. Remove cover behind left hand control assembly.
3. Loosen switch mounting screws slightly, so switch can
be moved but is still held in place.
PTS

4. Pivot switch towards cam until switch actuates,

signified by a " c l i c k " sound. Move switch back until
switch contacts reset, again signified by a "click"
sound.
» / TO
/ PIVOT VALVE
LOCKNUT
5. Tighten mounting screws.
6. Install cover, remove wheel chocks and connect
TO
T R A V E R S E VALVE battery.
When adjusted properly, the switch will actuate before the
valve spool moves .030" (0.7mm). This will start the ac-
cessory pump and motor before the valve ports open.
TVSR & T V S L
SWITCH R O L L E R S PTS SWITCH R O L L E R

CAMS CAM
R O L L E R S SAME ROLLER CENTERED
DISTANCE FROM IN INDENT
CAM L O B E
ILLUSTRATION 2.5-1

Crown 1989 PF-8266-1 Printed in U.S.A.-

M2.5 - 19 - 001 M2.5 -19 - 001

 <2J\QUJh MAINTENANCE

Control Levers
Adjust cams and switches before adjusting control levers.
1. Disconnect battery and chock wheels.
2. Remove cover behind left hand assembly.
3. Loosen locknuts on both ends of adjusting rod be-
tween control lever and cam assembly.
4. Turn adjusting rod so lever is centered in slot of
housing.
5. Tighten locknuts to secure adjustment.

6. Install cover, remove wheel chocks and connect

battery.
COMPONENT R E P L A C E M E N T

Switches
1. Disconnect battery and chock wheels.
2. Remove cover behind left hand control assembly.
3. Disconnect wires from switch to be replaced.
4. Remove mounting screws and remove switch.

5. Position replacement switch on plate and install

mounting screws.
6. Adjust switch as described in ADJUSTMENTS.
7. Connect wires to switch common (C) and normally
open (NO) terminals.
8. Install cover, remove wheel chocks and connect
battery.
Control Levers
Control lever replacement procedures are described in the
LEFT HAND CONTROL ASSEMBLY section (M4.5) of this
manual.

Crown 1989 PF-8266-2 Printed in U . S . A :

M2.5 - 19 - 002 M2.5 - 19 - 002

 OlOUJh MAINTENANCE

MOTOR—HYDRAULIC (ROSS)

2 6 9 8 3
ILLUSTRATION 2.6-1

Overhaul the motor only in a clean, dust-free location, using

clean tools and equipment. Dirt or grit will damage the highly DISASSEMBLY
polished machined surfaces and will result in leakage or
premature failure of this hydraulic motor. (Re'erto Illustration 2.6-1)

Before disconnecting the hydraulic lines, clean port area of Gerotor End
motor. Check shaft and key slot and remove any burrs, nicks
or sharp edges and polish around the key slot. Drain all oil 1. Place motor in vise and clamp across edge of flange with
from motor, then plug ports before disassembly. output shaft down. Refer to Illustration 2.6-2.

NOTE

The motor should be placed in a vise during

disassembly. When clamping, use protective de-
vices on vise jaws such as special soft jaws,
pieces of hard rubber or boards. Follow clamping
procedures explained throughout this section.

ILLUSTRATION 2.6-2

Crown 1984 PF-5855-1 Rev. 1/94 Printed in USJ

03 R E V . 1/94
M2.6-18-020 M2.6- 18-02C
 MAINTENANCE

2. Remove cap screws (index 19), seal washers (index NOTE

18).
Do not use an impact wrench on these screws
3. Remove end cap (index 16). Separate seal (index 12) as rounded heads or broken sockets may result.
from the end cap.
If higher torque is required to break the screws
4. Remove gerotor (index 15). Separate seal (index 12) loose, heat may be needed. When heated, the
from gerotor. thread locking adhesive partially melts and the
torque required to remove the screw is greatly
5. Disassemble the drive spacer (index 17) and remove
reduced. Follow the instructions carefully and
drive shaft (index 13).
be careful not to overheat the housing as per-
6. Remove wear plate spacer (index 14) and separate manent damage could result.
seal (index 12) from the housing (index 11).
Use a small flame propane torch to heat the
Shaft End area of the housing where the screw is lodged.
Refer to Illustration 2.6-4. Apply torque to the
1. Reposition the motor in the vise clamping across the
9crew with a 5/16"-12 point socket wrench
port areas as shown in Illustration 2.6-3.
gradually. Apply heat for 8 to 10 seconds. As
scon as the screw breaks loose, remove heat
from the housing. Continue turning the screw
until it is completely removed.

PROPANE *4V ^
TORCH MOUNTING FLANGE

ILLUSTRATION 2.6-4
3. Remove the motor from the vise and place on a clean
flat surface. Carefully remove the mounting flange
from the housing, refer to Illustration 2.6-4. The oil seal
(index 5) will come off with the flange.
ILLUSTRATION 2.6-3
NOTE
/f\ CAUTION
The bearing race (index 6) may come off with
Excessive clamping pressure on the sides of the the flange. Remove this with your hand. If the
housing can cause distortion. race is difficult to remove, gently tap on the race
with a rubber mallet.
NOTE
4. Remove the output shaft (index 9) from housing (index
Shaft could drop from housing when clamped
11).
as shown in Illustration 2.6-3. Tilt bottom.
Secure shaft accordingly. 5. Disassemble bearing race (index 6) and thrust needle
bearing (index 7) from shaft (index 9).
2. Remove the four (4) cap screws (index 1) from the
mounting flange. These screws use a thread locking
adhesive. 300to400 inch pounds of torque will be re-
quired to break loose the screws.

Crown 1984 PF-S855-2 Rev. 7/89 Prinled in U.S.A."

02 REV. 7/89
M2.6 -18 - 021 M2.6 - 18 - 021
 CROUJh MAINTENANCE

6. A metal plug (index 10) and seal (index 8) plugs a NOTE

machining hole in the housing. It is not necessary to
Do not permit any hydraulic oil to get into the
remove the plug housing assembly unless leakage
four (4) tapped holes in the face of the housing.
occurs around the plug. To remove the plug, insert a
3/16" Allen wrench through the left port opening and Assemble the needle thrust bearing (index 7) and the
push it out. Refer to Illustration 2.6-5. : e a - -g 'ace (index 6) onto :ne o j t p j ' . s~a~. Align the
timing dot located on the end of the output shaft with
a land to the right of any forward valve slot. Refer to
Illustration 2.6-6. Insert all three (3) components into
the housing together. The bearing races must rotate
freely when in position.
PLUG
ASSEMBLY

T I M I N G DOT
DOT IN LINE W I T H
L A N D TO RIGHT OF A N Y
- O R W A R D V A L V I N G SLOT)

ILLUSTRATION 2.6-5

Inspection FORWARD
VALVING
Check all mating surfaces. Replace any parts that have SLOT

scratches or burrs that could cause leakage or damage.

Clean all metal parts in clean solvent. Blow dry with air. Do
not wipe parts with cloth or paper towel because lint or
other matter can get into the hydraulic system and cause
damage. Check around the keyslot and chamfered area
of the shaft for burrs, nicks or sharp edges that can damage
ILLUSTRATION 2.6-6
the seals when reassembling. Remove nicks or burrs with
a hard smooth stone (such as an Arkansas stone). Do not 4. Clean mounting flange of all loose metalic chips, par-
try to file or grind motor parts. ticles, dirt or other contamination, including hydraulic
oil. During cleaning process, visually check mounting
NOTE
flange, dust seal and pressure seal (refer to Illustra-
Lubricate all seals with petroleum jelly such as tion 2.6-7) for scratches, marks or cuts that might
Vaseline. Use new seals when reassembling cause leakage. If the flange or seals are damaged
the motor. Refer to service manual page entitled replace mounting flange.
"Hydraulic Motor" for appropriate replacement
part numbers. FLANGE PRESSURE SEAL
INNER SIDE
REASSEMBLY

Shaft End
1. If you remove the plug assembly as described in step
6 of the shaft end disassembly, lubricate the new seal
(index 8) and install on the plug housing (index 10). In-
stall the seal in the plug groove closest to the end of
the plug. Insert the plug assembly into the housing (in-
dex 11) with the empty groove first until the plug's trail-
ing end is flush with the face of the housing. Be careful
not to damage the seal during assembly. FLANGE
DUST
OUTER SIDE
SEAL
2. Lubricate output shaft (index 9) with hydraulic oil.
ILLUSTRATION 2.6-7

-
Crown 1984 PF-5855-3 Rev. 7/89 Printed in U.S.A.

02 REV. 7/89
M2.6 - 18 - 022 M2.6 - 18 - 022
 CJlQWh MAINTENANCE

5. Inspect seal (index 5) for damage (if damaged, Gerotor End

replace) and install into flange.
1. Clamp housing in vise as shown in Illustration 2.6-2.
6. Apply thread locking adhesive (Crown 61004-12) to the
2. Pour approximately 35cc of clean hydraulic oil in out-
four (4) tapped holes in the housing. Wipe off excess
put shaft cavity.
adhesive from housing face using a non-petroleum
base solvent. Do not apply adhesive to threads more 3. Install the seal (index 12) into the housing seal groove.
than 15 minutes before installing screws. If housing Avoid twisting the seal during installation.
stands for more than 15 minutes, repeat application.
4. Insert drive (index 13), observing proper timing pro-
7. Before assembling the mounting flange assembly over cedure. Refer to Illustration 2.6-9 and timing pro-
the shaft, place a protective sleeve or bullet over the cedure. The timing dot must be exposed after shaft is
shaft. Lubricate the space between dust seals and installed.
pressure seal, refer to Illustration 2.6-8, as well as the
5. Position the wear plate spacer (index 14) carefully on
lips of both seals. Rotate the flange slowly while
the housing. Align bolt holes. Be careful not to
pushing down over the shaft. Be careful not to invert
disengage housing seal (index 12) during alignment.
the seal lip or damage seals.
6. Install the gerotor seal (index 12) into the seal groove
8. Clamp motor in vise as shown in Illustration 2.6-3,
of the gerotor (index 15).
making sure the shaft cannot fall out. Install dry screws
(index 1) and alternately torque immediately to 250 7. Place the gerotor on the wear plate, seal side first.
inch pounds. Observe proper timing procedure. Refer to Illustration
2.6-9 and timing procedure.

DUST
SEAL SLEEVE GEROTOR
SEAL
OR B U L L E T

STAR POINT
ALIGN WITH
DRIVING T I M I N G DOT

TIMING
DOT-DRIVE
(MARK ANY
LIGHTLY RESSURE SEAL DRIVE TOOTH)
DRIVE ALIGN WITH
LUBRICATE
SEALS. A F T T I M I N G DOT
R TO I N S T A L L I N G
WEAR PLATE.
SPACER
BEARING PLATE
RACE

HOUSING
ILLUSTRATION 2.6-8
TIMING
DOT-SHAFT
NARROW LAND SEE I L L U S T R A T I O N
2.6-6

FORWARD
VALVING
SLOT

WIDE LAND

ILLUSTRATION 2.6-9

Crown 1984 P F - 5 8 S 5 - t Rev. 7/89 Printed in U.S.A.*

02 REV. 7/89
M2.6 - 18 - 023 M2.6 - 18 - 023
 OVQlDh MAINTENANCE

Gerotor End (Con't.)

TIMING PROCEDURES
(Refer to Illustration 2.6-9)
Note timing dot on exposed end of output shaft (index 9).
Install drive shaft with timing dot (located on drive tooth)
aligned with timing dot on output shaft. Install wear plate.
Position gerotor (index 15) with any gerotor star point align
with timing dot on drive shaft (index 13). Turn the gerotor
to line up bolt holes with the wear plate spacer holes and
the housing bolt holes. Be careful not to disengage gerotor
star (part of index 15) from drive shaft (index 13) or disturb
gerotor seal (index 12).

8. Insert drive spacer (index 17) into gerotor.

9. Install end cap seal (index 12) into seal groove on face
of end cap (index 16).
10. Install cap screws (index 19) with seal washe-s (index
18) and pre-tighten all seven (7) screws to 15-40 inch
pound of torque. When you are sure all seals (index
12) are properly seated, sequentially torque all screws
to 200 inch pounds. Refer to Illustration 2.6-10 for
tightening pattern.

BOLT T O R Q U I N G
SEQUENCE

ILLUSTRATION 2.6-10

Crown 1984 PF-5855-5 Rev. 7/89 Printed in U.S.A.*

02 REV. 7/89
M2.6 -18 - 024 M2.6 -18 - 024
 MAINTENANCE

ENLARGED SECTIONAL VIEW

OF INDEXES 3 & 5

ILLUSTRATION 1

Preparation Before Disassembly CAUTION

Before you disassemble the hydraulic motor or any of its Be extremely careful when using any solvent. Even
components read this entire maintenance section. It pro- a small explosion or fire could cause injury or death.
vides important information on parts and procedures you Always wear eye protection and be sure to comply
will need to know to service the hydraulic motor. Refer to with OSHA or other maximum air pressure
the tool list for tools and other items required to service the requirements.
hydraulic motor and have them available.
/t\ WARNING
Thoroughly clean off all outside dirt, especially from around
A/ever sfeam or high pressure wash hydraulic com-
fittings and hose connections, before disconnecting and
. ponents. Do not force or abuse closely fitted parts.
removing the hydraulic motor. Remove rust or corrosion
from coupling shaft. Remove coupling shaft connections Keep parts separate to avoid nicks and burrs. Discard all
and hose fittings and immediately plug port holes and fluid seals and seal rings as they are removed from the unit.
lines. Remove the hydraulic motor from truck, drain it of Replace all seals, seal rings and any damaged parts with
fluid and take it to a clean work surface. Clean and dry the approved service parts.
unit before you start to disassemble the unit. As you
disassemble the unit clean all parts, except seals, in clean
petroleum-based solvent, and blow them dry.

-
Crown 1988 PF-8069-1 Printed In U . S A .

M2.6 - 18 - 040 M2.6 - 18 - 040

 MAINTENANCE

TROUBLESHOOTING CHART
Trouble Cause Remedy
Oil Leakage 1. Hose fittings loose, worn or Check & replace damaged fittings
damaged or " 0 " Rings. Torque to
manufacturers specifications.
2. Oil seal rings (4) deteriorated by Replace oil seal rings by
excess heat disassembling unit.
3. Bolt (1) loose or its sealing area (a) Loosen then tighten single bolt to
deteriorated by corrosion torque specification.
(b) Replace bolt.
4. Internal shaft seal (16) worn or Replace seal. Disassembly of unit
damaged necessary.
5. Worn coupling shaft (11) and in- Replace coupling shaft and seal
terna' seal (16) by disassembling unit.

Significant loss of speed under load 1. Lack of sufficient oil supply (a) Check for faulty relief valve and
adjust or replace as required.
(b) Check for and repair worn pump.

(c) Check for and use correct oil for

temperature of operation.
2. High internal motor leakage (a) Replace worn rotor set by
disassembling unit.
3. Severely worn or damaged inter- Replace rotor set, drive link and
nal splines coupling shaft by disassembling
unit.

4. Excessive heat Locate excessive heat source

(usually a restriction) in the
system and correct the condition.
Low mechanical efficiency or undue 1. Line blockage Locate blockage source and
high pressure required to operate repair or replace.
unit
2. Internal interference Disassemble unit, identify and
remedy cause and repair, replac-
ing parts as necessary.

3. Lack of pumping pressure Check for and repair worn pump

4. Excessive binding or loading in Locate source and eliminate
system external to hydraulic motor cause.

/ | \ CAUTION
If the hydraulic system fluid becomes overheated (in excess of 200°F [93.3°C]), seals in the
system can shrink, harden or crack, thus losing their sealing ability.

Crown 1988 PF-8069-2 Printed in U.S.A.*

M2.6 -18 - 041 M2.6 - 18 - 041

 erawn MAINTENANCE

Tools and Materials Required for Servicing

Clean, petroleum-based solvent SAE 10W40 SE o r S F oil
Emery paper Special bearing mandrel (See illustration below)
Vise with soft jaws Feeler gage .005 inch (.13mm)
Air pressure source Blind hole bearing puller for 1.06 inch (26.9mm) and
Arbor press 1.62 inch (41.1mm) diameter bearing/bushing.

Screwdriver Clean corrosion resistant grease. Recommended

grease is E/M Lubricant #K-70M, Crown #107334.
Masking tape
NOTE
Breaker bar
The available service seal kits include the recom-
Torque wrench—ft. lbs. (N m) mended grease as a grease pack.
Sockets: 1/2 or 9/16 inch thin wall, 1 inch /t\ CAUTION
Allen Sockets: 3/16, 3/8 inch Mixing greases that have different bases can be
detrimental to bearing life.
Adjustable crescent wrench or hose fitting wrenches

Special Bearing Mandrel

0 J, ~f6 MIN.

ZERO RADIUS
(UNDERCUT IE
NECESSARY)

KNURL

ZERO RADIUS
(UNDERCUT IE
NECESSARY)
v
~O30"X 45'
(TYR 4 PLACES)
1.295-

Crown 1988 PF-8069-3 Printed in U.S.A.*

M2.6 - 18 - 042 M2.6 - 18 - 042

 CRQUJh MAINTENANCE

Disassembly and Inspection

(Refer also to illustration 1)
1. Place the hydraulic motor in a soft jawed vice, with
coupling shaft (11) pointed down and the vise jaws •

clamping firmly on the sides of the housing (18) moun-

ting flange or port bosses.

/j\ CAUTION
If the hydraulic motor is not firmly held in the vise,
• 1
it could be dislodged during the service pro-
cedures, causing injury. . iff

m •w
2. Scribe an alignment mark down and across the
hydraulic motor components from end cover (2) to .4 'v-B

housing (18) to facilitate reassembly orientation .*, here

required. Refer to illustration 2. ILLUSTRATION 4

4. Remove end cover assembly (2) and seal ring (4).

Discard seal ring. Refer to illustration 5.

ILLUSTRATION 2

3. Remove the five special ring head bolts (1) using an

appropriate 1/2 inch size socket. Refer to illustration ILLUSTRATION 5
3. Inspect bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts. Refer to 5. Thoroughly wash end cover (2) in proper solvent and
illustration 4. blow dry. Inspect end cover for cracks and the bolt
head recesses for good bolt head sealing surfaces.
Replace end cover if necessary.

NOTE
A polished pattern (not scratches) on the cover
from rotation of the commutator (5) is normal.
Discoloration w o u l d indicate excess fluid
temperature, thermal shock, or excess speed and
require system investigation for cause and close
inspection of end cover, commutator, manifold and
rotor set.

ILLUSTRATION 3

Crown 1988 PF-8069-4 Printed in U.S.A.*

M2.6 - 18 - 043 M2.6 - 18 - 043

 erawn MAINTENANCE

6. Remove commutator ring (6) as shown in illustration

6. Inspect commutator ring for cracks or burrs.

ILLUSTRATION 8

ILLUSTRATION 6 8. Remove manifold (7) and inspect for cracks surface

scoring, brinelling or spalling. Replace manifold if any
7. Remove commutator (5) and seal ring (3). Remove of these conditions exist. Refer to illustration 9. A
seal ring from commutator, using an air hose to blow polished pattern on the ground surfaces from com-
air into ring groove until seal ring is lifted out and mutator or rotor rotation is normal. Remove and
discard seal ring. Inspect commutator for cracks or . discard the seal rings (4) that are on both sides of the
burrs, wear, scoring, spalling or brinelling. If any of manifold.
these conditions exist, replace commutator and com-
NOTE
mutator ring as a matched set. Refer to illustrations 7
and 8. The manifold is constructed of plates bonded
together to form an integral component not sub-
ject to further disassembly for service. Compare
configuration of both sides of the manifold to
ensure that same surface is reassembled against
the rotor set.

ILLUSTRATION 7

ILLUSTRATION 9

Crown 1988 PF-8069-5 Printed in U.S.A.*

M2.6 - 18 - 044 M2.6 - 18 - 044

 MAINTENANCE
9. Remove rotor set (8) and wearplate (9) together to re- hydraulic motor. Marking all rotor components and
tain the rotor set in its assembled form, maintaining mating spline components for exact repositioning
the same rotor vane (8C) to stator (8B) contact sur- at assembly will ensure maximum wear life and
faces. Refer to illustration 10. The drive link (10) may performance of rotor set and hydraulic motor.
come away from the coupling shaft (11) with the rotor
NOTE
set, and wearplate. You may have to shift the rotor set
on the wearplate to work the drive link out of the rotor A polished pattern on the wear plate from rotor
(8A) and wearplate. Refer to illustration 11. Inspect the rotation is normal.
rotor set in its assembled form for nicks, scoring, or
10. Place rotor set (8) and wear plate (9) on a flat surface
spalling on any surface and for broken or worn splines.
and center rotor (8A) in stator (8B) such that two rotor
If the rotor set component requires replacement, the
lobes (180 degrees apart) and a roller vane (8C)
complete rotor set must be replaced as it is a match-
centerline are on the same stator centerline. Check the
ed set. Inspect the wearplate for cracks, brinelling, or
rotor lobe to roller vane clearance with a feeler gage
scoring. Discard seal ring (4) that is between the rotor
at this common centerline. If there is more than .005
set and wearplate.
inches (0.13mm) of clearance, replace rotor set. Refer
to illustration 12.

ILLUSTRATION 10

ILLUSTRATION 12

11. Remove drive link (10) from coupling shaft (11) if it was
not removed with rotor set and wear plate. Inspect
drive link for cracks and worn or damaged splines. No
perceptible backlash (play) should be noted between
mating spline parts. Refer to illustration 13.

ILLUSTRATION 11

NOTE

The rotor set (8) components may become

disassembled during service procedures. Marking
the surface of the rotor and stator that is facing UP,
with etching ink or grease pencil before removal
f r o m hydraulic motor will ensure correct
reassembly of rotor into stator and rotor set into ILLUSTRATION 13

Crown 1988 PF-8069-6 Printed in U.S.A."

M2.6 - 18 - 045 M2.6 - 18 - 045

 MAINTENANCE

12. Check exposed portion of coupling shaft (11) to be

sure you have removed all signs of rust and corrosion
which might prevent its withdrawal through the seal
and bearing. Crocus cloth or fine emery paper may be
used as shown in illustration 14. Also remove the key
(12).

ILLUSTRATION 16

14. Remove and discard seal ring (4) from housing (18).
15. Remove thrust bearing (14) and thrust washer (15)
from the unit. Inspect for wear, brinelling, corrosion
and a full complement of retained rollers. Refer to
illustration 17.
ILLUSTRATION 14

13. Remove coupling shaft (11), by pushing on the output

end of shaft. Refer to illustration 15. Inspect coupling
shaft bearing and seal surfaces for spalling, nicks,
grooves, severe wear or corrosion and discoloration.
Inspect for damaged or worn internal and external
splines or keyway. Refer to illustration 16 for critical
inspection areas. Replace coupling shaft if any of
these conditions exist.

NOTE
Minor shaft wear in seal area is permissible. If wear
exceeds .020 inches (0.51mm) diametrically,
replace coupling shaft. A slight "polish" is per-
missible in the shaft bearing areas. Anything more ILLUSTRATION 17
would require coupling shaft replacement.
16. Remove seal (16) and back up washer (17) from hous-
ing (18). Discard both. Refer to illustration 18.

ILLUSTRATION 15

ILLUSTRATION 18

Crown 1988 PF-8059-7 Printed in U.S.A.'

M2.6 - 18 - 046 M2.6 - 18 - 046

 MAINTENANCE
17. Remove housing (18) from vise, invert it and remove NOTE
and discard seal (20). A blind hole bearing or seal
puller required as shown in illustration 19. The depth or location of bearing/bushing (13) in
relation to the housing wear plate surface and the
depth or location of bearing/bushing (19) in rela-
tion to the beginning of bearing/bushing counter
bore should be measured and noted before remov-
ing the bearings/bushings. This will facilitate the
correct reassembly if new bearings/bushings are
required. Refer to illustration 23.

ILLUSTRATION 19
18. Inspect housing (18) assembly for cracks. Check the
machined surfaces for nicks, burrs, brinelling or cor-
rosion. Remove burrs that can be removed without
changing dimensional characteristics. Inspect tappec
holes for thread damage. Refer to illustration 20. If the
housing is defective in these areas, discard the hous-
ILLUSTRATION 21
ing assembly.

ILLUSTRATION 22
ILLUSTRATION 20
19. If the housing (18) assembly has passec inspection to
this point, inspect the housing bearings/bushings (19)
and (13). If the unit is equipped with roller bearings,
make sure they are captured in the housing cavity by
the two thrust washers (14) and thrust bearing (15).
The bearing rollers must be firmly retained in the bear-
ing cages, but must rotate and orbit freely. All rollers
and thrust washers must be free of brinelling and cor-
rosion. Refer to illustration 21. The #106650 hydraulic
motor bushing (19) or (13) to coupling shaft diametrical
clearance must not exceed .010 inch (025mm). Refer
to illustration 22. A bearing, bushing, or thrust washer
that does not pass inspection must be replaced. If the
housing has passed this inspection the disassembly
ILLUSTRATION 23
of the hydraulic motor is completed.

Crown 1988 PF-8069-8 Printed in U.S.A.*

M2.6 - 18 - 047 M2.6 - 18 - 047

 MAINTENANCE

20. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18)
without damaging the housing. Remove thrust
washers (15) and thrust bearing (14) if they were
previously retained in the housing by bearing/bushing
(13). Refer to illustration 24 and 25.

ILLUSTRATION 24

ILLUSTRATION 25

-
Crown 1988 PF-8069-9 Printed in U.S.A.

M2.6 - 18 - 048 M2.6 - 18 - 048

 MAINTENANCE

Reassembly
Replace all seals and seal rings with new ones each time
you reassemble the hydraulic motor. Lubricate all seals
and seal rings with SAE10W40 oil or clean grease before
assembly.
NOTE
Individual seals and seal rings as well as a com-
plete seal kit (107300 [illustration 26]) are
available.

ILLUSTRATION 27

NOTE
Bearing mandrel must be pressed against the let-
tered end of bearing shell. Take care that the hous-
ing bore is square with the press base and the
bearing/bushing into the housing.
/ j \ CAUTION
If the bearing mandrel specified is not available and
alternate methods are used to press in bear-
ILLUSTRATION 26 ing/bushing (13) and (19), the bearing/bushing
depths specified must be achieved to insure ade-
/j\ WARNING quate bearing support and correct relationship to
adjacent components when assembled. Refer to
Unless otherwise indicated, do not oil or grease illustration 28.
parts before assembly.
Wash all parts in clean petroleum-based solvents before
assembly. Blow them dry with compressed air. Remove
any paint chips from mating surfaces of the end cover,
commutator set, manifold rotor set, wear plate and hous-
ing and from port and sealing areas.
/ t \ CAUTION
Be extremely careful when using any solvent. Even
a small explosion or fire could cause injury or death.
Always wear eye protection and be sure to comply
with OSHA or other requirements when working
with compressed air.
1. If the housing (18) bearing components were removed
for replacement, thoroughly coat and pack a new
ILLUSTRATION 28
outer bearing/bushing (19) with clean corrosion resis-
tant grease. Recommended grease is E/M Lubricant
#K-70M, Crown No. 107334. Press the new bear- NOTE
ing/bushing into the counterbore at the mounting Because the bearing/bushings (13) and (19) have
flange end of the housing, using a bearing mandrel a press fit into the housing they must be discarded
such as described in the illustration on page M2.6 -18 when removed. They must not be reused.
- 042. This bearing mandrel will seat the bear-
ing/bushing (19) into the housing to a required depth
of .151 '7.161" (3.84/4.09mm) from the end of the bear-
ing counterbore as shown in illustration 27.

Crown 1988 PF-8069-10 Primed in U.S.A.'

M2.6 -18 - 049 M2.6 - 18 - 049

 <2J\QUJh MAINTENANCE

2. The hydraulic motor inner housing bearing/bushing

(13) can now be pressed into its counterbore in hous-
ing (18) flush to .03 inch (.76mm) below the housing
wear plate contact face. Use the opposite end of the
bearing mandrel that was used to press in the outer
bearing/bushing (19). Refer to illustration 29.

ILLUSTRATION 31

5. Assemble a new backup washer (17) and new seal

(16) with '.he seal lip facing out, into their respective
counterbores in housing (18). Refer to illustration 32
and 33.

ILLUSTRATION 29
*

3. Apply a small amount of clean grease to a new dirt and

water seal (20) and press it into the housing (18) outer
bearing counterbore. It must be pressed in until its
flange is flush against the housing as shown in illustra-
tion 30.

ILLUSTRATION 32

ILLUSTRATION 30

4. Place housing (18) assembly into a soft jawed vise with

the coupling shaft bore down, clamping against the
mounting flange as shown in illustration 3 1 .

ILLUSTRATION 33

Crown 1988 PF-8069-11 Printed in U.S.A.*

M2.6- 1 8 - 0 5 0 M2.6 - 18 - 050

 MAINTENANCE

6. Assemble thrust washer (15) then thrust bearing (14)

that was removed from the hydraulic motor as shown
in illustration 34.

ILLUSTRATION 36

NOTE
:

ILLUSTRATION 34 ~-e : e = - ng (19) is not lubricated by the

system's hydraulic fluid. Be sure it is thoroughly
packed with the recommended grease, (107334).
7. Apply masking tape around splines or keyway on shaft
(11) to prevent damage to seal. Refer to illustration 35. The coupling shaft (11) will be flush or just below
the housing wear plate surface when properly
seated. The coupling shaft must rotate smoothly
on the thrust bearing package. Refer to illustration
37.

ILLUSTRATION 35

8. Be sure that a generous amount of clean corrosion

resistant grease has been applied to the lower (outer)
ILLUSTRATION 37
housing bearing/bushing (19). Install the coupling
shaft (11) into housing (18), seating it against the thrust
bearing (15) as shown in illustration 36.

Crown 1988 PF-8069-12 Printed in U.S.A.'

M2.6 -18 - 051 M2.6 -18 - 051

 MAINTENANCE

9. Apply a small amount of clean grease to a new seal NOTE

ring (4) and insert it into the housing (18) seal ring
Use the alignment marks put on the coupling shaft
groove as shown in illustration 38.
and drive link as described in the note after step
9. in "disassembly" to assemble the drive link
splines in their original position in the mating
coupling shaft splines.
11. Assemble wear plate (9) over the drive link (10) and
alignment studs onto the housing (18) as shown in
illustration 40.

ILLUSTRATION 38

NOTE
One or two alignment studs screwed finger tight
into housing (18) bolt holes, approximately 180
degrees apart, will facilitate the assembly and
alignment of components as required in the follow- ILLUSTRATION 40
ing procedures. The studs can be made by cutting
off the heads of either 3/8-24 UNF 2A or 5/16-24
12. Apply a small amount of clean grease to a new seal
UNF 2A bolts as required that are over .5 inch
ring (4) and assemble it into the seal ring groove on
(12.7mm) longer than the bolts (1) used in the
the wear plate side of the rotor set stator (8B). Refer
hydraulic motor.
to illustration 4 1 .
10. Install drive link (10) the long splined end down into the
coupling shaft (11) and engage the drive link splines
into mesh with the coupling shaft splines. Refer to
illustration 39.

ILLUSTRATION 41

LLUSTRATION 39

-
Crown 1988 PF-8069-13 Printed in U.S.A.

M2.6 - 18 - 052 M2.6 - 18 - 052

 crawn MAINTENANCE
13. Install the assembled rotor set (8) onto wear plate (9) B. If assembly alignment studs are not being utilized,
with rotor (8A) counterbore and seal ring side down. align stator bolt holes with wear plate and housing
Mesh splines with the drive link splines. Refer to il- bolt holes and turn two bolts (1) finger tight into bolt
lustration 42. It may be necessary to turn one align- holes approximately 180 degrees apart to retain
ment stud out of the housing (18) temporarily to stator and wear plate stationary.
assemble rotor set (8) or manifold (7) over the drive
link. C. Assemble the rotor (8A), counterbore down if ap-
plicable, into stator (8B), and onto wear plate (9)
with rotor splines meshed with drive link (10)
splines. Refer to illustration 44.

ILLUSTRATION 42

NOTE
ILLUSTRATION 44
The rotor set rotor counterbore side must be down
against wear plate for drive link clearance and to
NOTE
maintain the original rotor drive link spline contact.
A rotor set without a counterbore, which was not If the manifold side of the rotor was etched
etched before d sassembly can be reinstalled by during disassembly, this side should be up.
using the drive link spline pattern on the rotor If the rotor is not etched and does not have
splines (if apparent), to determine which side was a counterbore, use the drive link spline con-
down. The rotor set has a sea! ring groove on the tact pattern apparent on the rotor splines to
wear plate contact side of the stator (8B). determine the rotor side that must be against
the wear plate.
A disassembled rotor (8A) stator (83) and vanes (8C) that
cannot be readily assembled by hand can be assembled D. Assemble six vanes (8C), or as many vanes that
by the following procedures. will readily assemble into the stator vane pockets.
Refer to illustration 45.
A. Place stator (8B) onto wear plate (9) with seal ring
(4) side down, after following hydraulic motor
assembly procedures 1 through 12. Be sure the
seal ring is in place. Refer to illustration 43.

ILLUSTRATION

ILLUSTRATION 43

-
Crown 1988 PF-8069-14 Printed in U.S.A.

M2.6 - 18 - 053 M2.6 -18 - 053

 MAINTENANCE

/f\ WARNING NOTE

Excessive force used to push the rotor vanes The manifold (7) is made up of several plates
into place could shear off the coating applied bonded together permanently to form an integral
to the stator vane pockets. component. The manifold surface that must con-
tact the rotor set has its series of irregular shaped
E. Grasp the output end of coupling shaft (11) with
cavities on the largest circumference or circle
locking pliers or other appropriate turning device
around the inside diameter. The polished impres-
and rotate coupling shaft, drive link and rotor to
sion left on the manifold by the rotor set is another
seat the rotor and the assembled vanes (8C) into
indication of which surface must contact the rotor
stator (8B), creating the necessary clearance to
set.
assemble the seventh or full complement of seven
vanes. Assemble the seven vanes using mini - _ - 15. Assemble the manifold (7) over the alignment studs
force as shown in illustration 46. and drive link (10) and onto the rotor set. Be sure the
correct manifold surface is against the rotor set. Refer
to illustration 48.

ILLUSTRATION 46

F. Remove the two assembled bolts (1) if used to ILLUSTRATION 48

retain stator and wear plate.
16. Apply grease to a new seal ring (4) and insert it in the
14. Apply clean grease to a new seal ring (4) and assem-
seal ring groove exposed on the manifold as shown
ble it in the seal ring groove in the rotor set contact side
in illustration 49.
of manifold (7) as shown in illustration 47.

ILLUSTRATION 49
ILLUSTRATION 47

Crown 1988 PF-8069-15 Printed in U.S.A.*

M2.6 - 1 8 - 0 5 4 M2.6 - 1 8 - 0 5 4
 MAINTENANCE

17. Assemble the commutator ring (6) over alignment 19. Assemble a new seal ring (4) into end cover (2) and
studs onto the manifold. Refer to illustration 50. assemble end cover over the alignment studs and onto
the commutator set. Refer to illustrations 53 and 54.
Be sure the cover holes are aligned with the 5 threaded
holes in housing (18). The correct 5 bolt end cover bolt
hole relationship to housing port bosses is shown in
illustration 55.

ILLUSTRATION 50

18. Assemble a n e w seal ring (3) flat s i d e u p . into com-

mutator (5) and assemble commutator over the end of
drive link (10) onto manifold (7) with seal ring side up
as shown in illustrations 51 and 52. ILLUSTRATION 53

Crown 1988 PF-8069-16 Primed in U.S.A.*

M2.6 - 18 - 055 M2.6 -18 - 055

 MAINTENANCE

ILLUSTRATION 56

-4?

ILLUSTRATION 55

ILLUSTRATION 57
NOTE
Use the line you previously scribed on the cover Final Checks
to radially align the end cover into its original
position. 1. Pressurize the hydraulic motor with 100 p.s.i. dry air
or nitrogen and submerge in solvent to check for ex-
20. Assemble the 5 bolts (1) and screw in finger tight. ternal leaks.
Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and 2. Check hydraulic motor for rotation. Torque required
progressively tighten the bolts to pull the end cover to rotate coupling shaft should not be more than 50 ft.
and other components into place with a final torque of lbs. (68 Nm).
22-26 ft. lbs. (30-35 Nm) for the five 5/16 24 threaded 3. Pressure port with " A " cast under it on housing (18)
bolts. Refer to illustrations 56 and 57. is for clockwise coupling shaft rotation as viewed from
the output end of coupling shaft. Pressure port with
" B " cast under it is for counterclockwise coupling
shaft rotation.
4. Use test stand if available, to check operation of the
hydraulic motor.

Crown 1988 PF-8069-17 Printed in U.aA."

M2.6 - 18 - 056 M2.6 - 18 - 056

 crauiw ACCUMULATOR

The Accumulator is a device in which compressed gas and Remove cap of gas valve, then attach charging hose to
hydraulic oil is stored for the purpose of absorbing shock in nitrogen bottle and to gas valve using the following instruc-
hydraulic circuits or storing and releasing pressurized oil. As tions. Refer to Illustration 1. Procedure is similar when using
a shock absorber, the accumulator relieves pressure surges only charging hose with or without other accessories.
in the circuit by the compression of inert gas. As a storage
unit, the accumulator can deliver limited amounts of pressur- 1. Use thread sealing and lubricating compound on pipe
ized oil without the need of energizing the systems hydraulic threads of gage.
pump.
2. Back gas chuck stem all the way out before attaching
The main raise circuit uses an accumulator as a shock assembly to accumulator gas valve.
absorberto smooth the lift to stop or lowerto stop transitions.
The brake circuit accumulator has the capability of storing 3. Use wrench to tighten gas chuck swivel nut onto gas
enough pressurized oil to release the drive and load wheel valve. Close bleeder valve.
brakes. The traverse circuit accumulator provides a cushion
effect to obtain a smooth transition from traverse to fork 4. Turn gas chuck stem all the way down, which will
extend or retract. depress core in accumulator gas valve.

Precharging 5. Only crack open nitrogen bottle valve to slowly fill

accumulator. Shut off when gage indicates desired
Use an inert gas, such as nitrogen for precharging accumu- precharge. Lift/lower and brake accumulators are to be
lators. Size T " bottle dry nitrogen, 300 cu. ft., 2600 PSI charged to 350 PSI. Traverse cushion accumulator is
recommended. to be charged to 100 PSI.

6. If desired precharge pressure is exceeded, make sure

nitrogen bottle valve is closed, then open bleeder valve
(opposite gas valve, below gage) slightly, but only
momentarily, to reduce pressure.

7. Before loosening swivel nut, turn gas chuck stem out all
the way, then open bleeder valve.

8. Loosen swivel nut, remove assembly.

9. When precharging has been completed, replace cap

on gas valve.

/f\ CAUTION
ILLUSTRATION 1 Do not loop or twist hoses as it will stiffen when
gas pressure is released from nitrogen bottle.

Never loosen swivel nut attached to gas valve in

accumulator without first backing gas chuck stem
out all the way.

Do not reduce accumulator precharge by de-

pressing valve core (high pressure may rupture
rubber valve seat).

5939

Crown 1988 PF8179 Rev. 6/03 Printed in U.S.A.

02 R E V . 6/03
M2.6-19.0-001 M2.6-19.0-001